Complete Quality Manual Vol 2 Rev. 2010

THIS QUALITY MANUAL IS THE ONLY CONTROLLED AND VALID VERSION.
ALL OTHER VERSIONS ARE CONSIDERED TO BE UNCONTROLLED AND MAY NOT BE USED FOR WORK CONTROLLING PURPOSES. DOCUMENT NO. MACO-QM-001 th 01 April 2009
QA / QC MANUAL VOL. 2 CONSTRUCTION PROCEDURES
KINGDOM OF SAUDI ARABIA
P.O. BOX 10257, DAMMAM 31433 KINGDOM OF SAUDI ARABIA Tel. No. +966 3 8417007 Fax. No. +966 3 8423281
DOCUMENT NO. MACO-QM-001
REV. 0
THIS QUALITY MANUAL IS THE ONLY CONTROLLED AND VALID VERSION. ALL OTHER VERSIONS ARE CONSIDERED TO BE UNCONTROLLED AND MAY NOT BE USED FOR WORK CONTROLLING PURPOSES. DOCUMENT NO. MACO-QM-001 th 01 APRIL 2009
QA/QC MANUAL VOL. 2 CONSTRUCTION PROCEDURES
P.O. BOX 10257, DAMMAM 31433 KINGDOM OF SAUDI ARABIA Tel. No. +966 3 8417007 Fax. No. +966 3 8423281
1 2 3 1 2 3
ISSUED FOR APPROVAL QA/QC Quality Manual SIGNATURE/DATE

REVISION HISTORY:
Prepared By:
CHECKED BY
APPROVED BY
APPROVED BY
APT
YSB
NMZ
SMZ
Document Recipients:
1. Gen. Manager 2. Asst. Gen. Manager 3. Business Dev. Manager 4. Project Managers 5. QA/QC Department 6. Project Engineers
Revision 1 April 1, 2009
DOCUMENT NO. MACO-QM-001 VOL. 2
REV. 0
QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0
QUALITY ASSURANCE/QUALITY CONTROL MANUAL

MACO-QM-001
VOL. 2
APPROVAL SHEET
Description Prepared By: Approved By: Approved By: Approved By:
Name A. P. Togle
Designation
QA/QC Senior Engineer Manar Arabian Corp.
Signature
Date
Y.S. Bahrawy N. M. Zahrani S. M. Zahrani
Projects Gen. Manager Assistant General Manager General Manager
-i-
Quality Manual Vol. 2
MACO-QM-001
QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0
QUALITY ASSURANCE/QUALITY CONTROL MANUAL MACO-QM-001

VOL. 2
REVISION HISTORY
Revision No. 0 1 2
Purpose of Revision Submitted for Approval.
Issue Date April 01, 2009
-iiQuality Manual Vol. 2 MACO-QM-001
QUALITY CONTROL/ASSURANCE MANUAL Quality Construction Procedures

DOCUMENT No. MACO-QM-001 REV. 0
TABLE OF CONTENTS QUALITY CONSTRUCTION PROCEDURES
SL NO.
PROCEDURE DESCRIPTION CIVIL WORKS
DOCUMENT NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SURVEYING SITE PREPARATION EXCAVATION, TRENCHING, BACKFILLING & COMPACTING ASPHALT CONCRETE PAVING & BASE COURSE CONCRETE WORKS GROUTING WORKS PROTECTIVE COATING FOR BURIED CONCRETE WATERPROOFING, CAULKING AND SEALING PIPE INSTALLATION PROCEDURE CONCRETE BATCH PLANT MISCELLANEOUS METALS SITE NON-ELECTRICAL PROCEDURE STRUCTURAL STEEL JOINT SEALANTS PRESSURE TESTING THRUST BORING
Page 1 of 3
MACO-QCCP-001 MACO-QCCP-002 MACO-QCCP-003 MACO-QCCP-004 MACO-QCCP-005 MACO-QCCP-006 MACO-QCCP-007 MACO-QCCP-008 MACO-QCCP-009 MACO-QCCP-010 MACO-QCCP-011 MACO-QCCP-012 MACO-QCCP-013 MACO-QCCP-014 MACO-QCCP-015 MACO-QCCP-016
MACO-QCP-TOC

SL NO.
PROCEDURE DESCRIPTION
DOCUMENT NO.
ELECTRICAL WORKS/INSTRUMENTATION WORKS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 WIRES AND CABLES INSTALLATION PROCEDURE GROUNDING SYSTEMS PROCEDURES LOW & MEDIUM VOLTAGE CABLES INSTALLATION PROCEDURE. SWITCH BOARDS AND PANEL BOARDS PROCEDURE INSTRUMENT AND WIRING PROCEDURE INSTRUMENT CONTROL PANEL PROCEDURE FIRE ALARM SYSTEMS INSTALLATION OF LIGHTING SYSTEM POWER SYSTEMS INSTALLATION OF JUNCTION BOXES AND DEVICES INSTALLATION OF CABLE TRAYS INSTALLATION OF COMMUNICATION SYSTEMS INSTALLATION OF CONDUITS AND FITTINGS INSTALLATION OF DISCONNECT SWITCHES LOW VOLTAGE MOTOR CONTROL CENTER INSTALLATION OF DRY-TYPE TRANSFORMERS INSTALLATION OF OIL-FILLED TYPE TRANSFORMERS
Page 2 of 3
MACO-QECP-001 MACO-QECP-002 MACO-QECP-003 MACO-QECP-004 MACO-QECP-005 MACO-QECP-006 MACO-QECP-007 MACO-QECP-008 MACO-QECP-009 MACO-QECP-010 MACO-QECP-011 MACO-QECP-012 MACO-QECP-013 MACO-QECP-014 MACO-QECP-015 MACO-QECP-016 MACO-QECP-017
MACO-QCP-TOC

18 19
INSTALLATION OF BATTERIES AND CHARGERS UNDERGROUND ELECTRICAL DUCT BANKS/MANHOLES
MACO-QECP-018 MACO-QECP-019
SL NO.
PROCEDURE DESCRIPTION MECHANICAL WORKS
DOCUMENT NO.
1 2 3 4 5 6 7 8 9 10 11 12 13
INSIDE BUILDING PIPING AND FITTINGS PIPE SLEEVES ANCHORS, SUPPORTS AND THRUST BLOCKS VIBRATION ISOLATION AIR HANDLING UNIT AIR COLLED CONDENSING UNIT PACKAGE AIR CONDENSING UNIT DUCTWORKS DUCTWORKS ACCESSORIES DUCTWORKS INSULATION MECHANICAL IDENTIFICATION TESTING AND BALANCING OF MECHANICAL SYSTEMS WELDING OF STRUCTURAL AND PIPING
-END-
MACO-QMCP-001 MACO-QMCP-002 MACO-QMCP-003 MACO-QMCP-004 MACO-QMCP-005 MACO-QMCP-006 MACO-QMCP-007 MACO-QMCP-008 MACO-QMCP-009 MACO-QMCP-010 MACO-QMCP-011 MACO-QMCP-012 MACO-QMCP-013
Page 3 of 3
MACO-QCP-TOC
QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

DOCUMENT TITLE:
PROCEDURE FOR: SURVEYING
DOCUMENT NO.: MACO-QCCP-001

Index 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 Scope Purpose References Definitions Responsibilities Procedure Documentation Page 2 2 2 2 2 3 4
001 ISSUE NO.
04/09/09 ISSUE DATE
MACO-QCCP-001 DESCRIPTION
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Surveying
Page 1 of 5
MACO-QCCP-001

SURVEYING
1 Scope
This quality procedure covers setting up reference points and bench marks, vertical and horizontal setting out of all buildings, trench work, utility installations and other works forming part of the contract. 2 Purpose
The purpose of this quality procedure is to provide a documented procedure for all activities related to Surveying. 3 References IFC Drawings : 4 Definitions None 5 Responsibilities 5.1 The QC inspector shall inspect and prepare RFI for Proponent representative to verify accuracy of gathered survey report/data. He shall also coordinate with the surveyor on a daily basis to monitor and identify field changes (if any). 5.2 The surveyor shall perform actual survey and ensure that gathered survey report/data are accurate, recorded and reported. His responsibility includes but no limited to: 5.2.1 Performing all surveys for the duration of the contract to ensure that levels and locations conform to the design drawings, and shop/working drawings approved by Proponent Representative. 5.2.2 Making formal written requests to Proponent for data on survey control points related to the project prior to construction. 5.2.3 Verifying the figures on all Proponent furnished data and documents before laying out the work. Site Plot Plan
Surveying
Page 2 of 5
MACO-QCCP-001

5.2.4 Informing Proponent Representative if the validity of any survey monument is threatened, and take the necessary steps. 5.2.5 Obtaining approval of Proponent Representative if any survey control points will be disturbed or destroyed by construction activities. 5.2.6 Maintaining all Proponent established reference points and bench marks at all times during construction. Under the direction of Proponent Representative, replace any survey monuments damaged or disturbed by construction activity. 5.2.7 6 Procedure 6.1 All horizontal and vertical reference points and monuments shall be established accurately within a maximum tolerance of 5mm vertically and 10mm horizontally. 6.2 If the validity of any survey monument is threatened, at least three (3) reference or witness markers shall be placed for each point likely to be disturbed. Survey notes shall be submitted listing the relative positions of the reference markers to each other and to the points referencing at least 48 hours prior to disturbing or threatening the validity of the monument. 6.3 All data and grade sheets shall be submitted to Proponent Representative at least 48 hours prior to construction. The grade sheets shall show the vertical and horizontal relationships between the stakes and the design reference points shown on the drawings. 6.4 All survey field notes shall be kept in field at all times for inspection by Proponent Representative. 6.5 Prior to beginning trenching operations and during the progress of the work, sufficient stakes shall be set and maintained to show conformance with the Drawings. All stakes shall be located in such a way that they will not be disturbed by construction operations. 6.6 Construction stakes shall be placed at each wye connection, cleanout, and at every 10 meter station. 6.7 All elevations shall be based on Proponent datum scale. Established survey controls shall be checked regularly against the existing monuments Preparing accurate as-built survey and submission drawings.
Surveying
Page 3 of 5
MACO-QCCP-001

prior to layout of new structures/utilities. Sufficient stakes shall be set and maintained before and during the progress of the work. 7 Documentation 7.1 Form QCCP-001-01-SC Survey Checklist
Surveying
Page 4 of 5
MACO-QCCP-001

SURVEY CHECKLIST QCCP-001-01-SC
Contract No.: _________________________ Location: _________________________
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
COORDINATES AS PER ACTUAL DRAWING
DIFF.
ELEVATION AS PER ACTUAL DRAWING
DIFF.
REMARKS
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SURVEYOR
Proponent REPRESENTATIVE
Signature: Name: Date:
Surveying
Page 5 of 5
MACO-QCCP-001

DOCUMENT TITLE:
PROCEDURE FOR: SITE PREPARATION

Index 1 2 3 4 5 6 7 Scope Purpose References Definitions Responsibilities Procedure Documentation Page 2 2 2 2 3 3 8
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Site Preparation
Page 1 of 9
MACO-QCCP-002

SITE PREPARATION
1 Scope
1.1 Clearing and Grubbing works shall include but not limited to: removal of all vegetation, brush, rubbish, large stones and metallic debris occurring within the limit of construction. 1.2 Earth work shall include, but not limited to: excavation of soil and rock, removal and disposal of all unsuitable soil and rock material from the work site, placing and compacting of fill materials imported from borrow pits, trenching and trench backfilling and grading the site to the required elevations as shown on the drawings. 2 Purpose
The purpose of this quality procedure is to provide a procedure for all activities related to Site Preparation. 3 References
ASTM C136: ASTM D 3017:
Sieve Analysis of Fine and Coarse Aggregate Test Method for Moisture Content of Soil and Soil Aggregate Test Method for CBR of Laboratory Compacted Soil Test Method for Maximum Index Density Test Method for Minimum Index Density Test Method for Density Test Method for Moisture Index Density
ASTM D 1883: ASTM D 4253: ASTM D 4254: ASTM D 2937: ASTM D 698:
Royal Commission Specifications: 02251 02220

Site Preparation
Compaction and Testing of Earthwork Structure Excavation and Backfill

Page 2 of 9 MACO-QCCP-002

02221
Trenching, Bedding, Backfilling and Compacting
Construction Specifications:
Definitions Dewatering removal of excess water from the saturated soil mass. Imported or Borrowed Fill Material sand or calcareous clay of marine origin, classified as marl, or combination of both sand and marl. The maximum particle size shall be 100 mm, or one half the lift thickness whichever is less. Select Fill Material inorganic material and shall have 100% passing the 50mm sieve and from 0-20% passing the no. 200 sieve. That portion of the material passing the No. 40 sieve shall have a maximum liquid limit of 35 and maximum plasticity index of 12. Atterbergs limits are not required for select fill material with less than 15% fines passing the No. 200 sieve. Clearing shall consist of satisfactory removal and disposal of all types of vegetation and debris including grass, brush and rubbish. Grubbing shall consist of the removal and disposal of slumps and roots to a depth of 0.5 meters below ground within the limit of construction.
5 5.1
Responsibilities The Civil Supervisor and/or Foreman are solely responsible for the activities related to Site Preparation. They shall coordinate with the surveyor for the reference and with the QC Inspector and/or Independent Testing Laboratory Technician for inspection or testing requirements. The QC Inspector shall inspect and prepare RFI for Proponent representative to witness/inspect tests related to backfilling and compacting. He shall also coordinate with the surveyor on a daily basis to monitor and identify field changes. The Independent Testing Laboratory Technician shall be responsible for all necessary tests in the field. He shall also be responsible in recording all test results and generate reports of all tests conducted.
5.2
5.3
Site Preparation
Page 3 of 9
MACO-QCCP-002

6 6.1
Procedure Surveying 6.1.1 Surveying shall be carried out in accordance to Work Procedure QCCP-001, Surveying. 6.2 Clearing and Grubbing 6.2.1 All types of vegetation and debris including grass, brush and rubbish within the limit of construction shall be satisfactorily removed and disposed. 6.2.2 Stumps and roots to a depth of 0.5 meters below the ground within the limit of construction shall also be removed and disposed. 6.3 Earthwork 6.3.1 Excavation 6.3.1.1 Unclassified Excavation work shall be performed to remove all material which includes soil and rock necessary for grading and construction in accordance with the lines and grades shown in the plan. 6.3.1.2 All unsuitable materials encountered during excavation shall be removed and replaced with suitable materials and compacted as required. Bottoms of excavation shall be smooth and free of loose earth or sand. 6.3.1.3 Excavation for structures shall be made accurately to the lines, grades and elevations shown on the drawings. Trenches and foundation pits shall be of sufficient size to permit the placement and removal of forms for the full length and width of structure footings. The upper 150mm of soil in the bottom of all footing trenches shall be compacted to the densities required. 6.3.1.4 Excavation work adjacent to the existing utilities as specified in the Proponent Construction Safety Manual will be carried out by Hand Excavation. 6.3.1.5 Trenching:
Site Preparation
Page 4 of 9
MACO-QCCP-002

6.3.1.5.1 Trenches shall be excavated with sufficient width to provide free working space at both sides of the trench and around the installed items as required for joining, backfilling and compacting. 6.3.2 Excavation of building foundations shall be carried out in accordance with foundation design drawings up to 2.5M depth to remove sabkha materials. Select fill material shall be used within 0.6m of bottom of elevation of foundations, spread footings, or slabs on grade. During excavation and compaction, ground water table shall be lowered to minimum 0.6m below the surface under compaction using Well Point System of dewatering. Dewatering shall be carried out in accordance to Method Statement submitted by Dewatering Sub-Contractor and approved by Proponent Representative. Side slope of excavations shall be cut true and straight and shall be graded to the proper cross section. Unsuitable soil slopes shall be removed and the slopes properly prepared. The bottom of excavations shall be graded to the elevations and configurations as shown on the Drawings. Over excavations shall be backfilled with suitable material and compacted. All excavated materials that are unsatisfactory for use as fill or backfill shall be disposed of at a location designated by Proponent. Unsuitable material encountered below grade shall be removed and replaced with suitable fill material and compacted to density requirements, unless the Geotechnical Report or Proponent Representative stipulates another procedure. Bottoms of excavations shall be smooth and free of loose earth or sand. Any soft or loose areas of insufficient bearing, as determined by Proponent Representative, shall be compacted to the density requirements. Excavation for structures shall be made accurately to the lines, grades and elevations shown in the drawings. Foundation pits shall be of sufficient size to permit the placement and removal of forms for the full length and width of structure footings and foundations shown. Rock or other hard material shall be cleaned of loose debris and cut to a firm surface, either level, stepped, or serrated, as shown or as directed. Loose disintegrated rock and thin strata shall
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
6.3.8
Site Preparation

be removed. When concrete or masonry is to be placed in an excavated area, special care shall be taken not to disturb the bottom of the excavation. Excavation to the final grade level shall not be made until just before the concrete or masonry is to be placed. 6.3.9 Excavation works adjacent to the existing utilities shall be carried out by hand.
6.3.10 All general areas (i.e. parking area, paved areas in addition to the building foot prints) shall be excavated to a minimum depth of 0.6m to remove existing sabkha to minimize the capillary action resulting in sabkha contamination of the backfilled areas. 6.4 Fill 6.4.1 Before placement of fill or backfill material, the following shall be observed: 6.4.1.1 Areas to receive fill shall be free of roots, trash, or other foreign material. 6.4.1.2 All areas to receive fill shall have the in-site soil proof rolled and inspected, after clearing and grubbing, for soft spots or loose zones. 6.4.1.3 All observed soft spots or loose zones shall be compacted in-place or excavated to firm soil and replaced with properly compacted fill. 6.4.2 Surface protection shall be provided where clean sand or dune sand is used for fill/bedding material. A cap layer of compacted cohesive material 150 to 300mm in thickness will be placed. Capping material shall have a maximum size of one-half lift thickness or 75mm, whichever is less, and shall have between 11-35% passing the No. 200 sieve. The capping material shall have a maximum liquid limit of 35 and maximum plasticity index of 12, as per ASTM D4318. Final slope shall be protected from erosion. 6.4.3 Fill materials shall be placed in successive horizontal lifts or layers not to exceed 200 mm in depth. Each layer, before starting the next, shall be leveled and smoothed by means of power driven graders, bulldozers or other suitable equipment. Hauling and spreading equipment shall be operated over the full width of each layer.
Site Preparation
Page 6 of 9
MACO-QCCP-002

6.4.4 Each layer of fill material shall be moistened or dried to uniform moisture content suitable for maximum compaction and then thoroughly compacted by rolling with tamping or pneumatic tired rollers or through wheel power rollers. At least one roller shall be operated continuously for each 100 cm, or fraction thereof, per hour. When several embankments, each of small area, are so isolated from each other that one roller cannot compact them satisfactorily, additional rollers shall be provided. All fills shall be compacted to 85% relative density as defined by ASTM D4253 and ASTM D4254 for cohesion-less materials, or 95% of the maximum density as determined by ASTM D1557 for cohesive materials. 6.4.5 Backfilling adjacent to structures shall be placed and compacted uniformly in such manner as to prevent wedging action or eccentric loading upon or adjacent to the structures. Slopes bounding or within areas to be backfilled shall be stepped or serrated to prevent sliding of the fill. During backfilling operations and in the formations of embankments, equipment that will overload the structure in passing over and compacting this fill shall not be used. 6.4.6 Prior to importing borrow materials and/or transporting fill material to Work site areas requiring fill, Proponent Representative reserves the right to inspect and test the fill material for conformity with the Specifications. Fill material which does not meet the requirements of Specifications shall not be used and, if on the worksite, shall be removed from the worksite. 6.5 Compaction and Testing 6.5.1 Prior to compaction of fill, a field test section using the intended compaction equipment shall be performed to determine the proper lift thickness to achieve the necessary density requirement. 6.5.2 In-place density and moisture content of soils shall be determined by the sand cone method per ASTM D1556, nuclear method per ASTM D2922, the rubber balloon method per ASTM D2167, or the drivecylinder method per ASTM D2937. Acceptance testing of in-place density and moisture content (field density testing) on compacted fill will be performed at the following rates: 6.5.2.1 Under all foundations one test every 1000 ft2. (90 m2.) of each lift. 6.5.2.2 Under area paving one test every 2000 ft2. (180m2.) each lift. of
Site Preparation
Page 7 of 9
MACO-QCCP-002

6.5.2.3 Road base and sub-base one test every 2000 ft2. (180m2.) of base or sub-base. 6.5.2.4 Backfill of trenches one test for every 50 linear ft. (15m) of each lift. 6.5.2.5 General fill one test every 5000 ft2. (460m2) of lift. each
6.5.3 As a minimum, at least one in-place density test shall be performed on every lift of fill and further placement shall not be allowed until the required density has been achieved. 6.5.4 The number of tests shall be increased if a visual inspection determines that the moisture content is not uniform or if the compacting effort is variable and not considered sufficient to attain the specified density. 7 7.1 Documentation Form No. QCCO-002-01-SP Site Preparation Checklist
Site Preparation
Page 8 of 9
MACO-QCCP-002

SITE PREPARATION CHECKLIST QCCP-002-01-SP
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2 3 4 5 6 7
All backfilling layer should be as of indicated in the contract drawing. Select fill is of Clint Specification or as approved by the client. Do not allow layers to exceed 300mm in thickness before compaction. Compact each layers in accordance with Royal Commission for Jubail & Yanbus Standards. The bottom of the trench shall be free of sharp or loose rock, debris or foreign matter. Cable or pipe shall be laid on a 150mm thick clean sand bed. The bed should be compacted uniformly to provide even bearing for pipes.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Site Preparation
Page 9 of 9
MACO-QCCP-002

DOCUMENT TITLE:
PROCEDURE FOR: EXCAVATION, TRENCHING, BACKFILLING AND COMPACTING

001 ISSUE NO.
03/21/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Excavation, Trenching, Backfilling and Compacting
Page 1 of 7
MACO-QCCP-003

EXCAVATION, TRENCHING, BACKFILLING AND COMPACTING

1 Scope
1.1 This procedure covers the trenching, excavation, backfilling and compacting building and other structures and utility lines; water and sewer pipes, drainage pipes, which also includes manholes, cleanouts and boxes, removal and disposal of excess excavation material and importing required bedding and fill material, installation of cable tiles and warning tapes. 2 Purpose
The purpose of this quality procedure is to provide a documented procedure for all activities related to Excavation, Trenching, Backfilling and Compacting. 3 References Sieve Analysis of Fine and Coarse Aggregate Test Method for Moisture Content of Soil and Soil Aggregate Test Method for CBR of Laboratory Compacted Soil Test Method for Maximum Index Density Test Method for Minimum Index Density Test Method for Density Test Method for Moisture Index Density Nuclear Test Method for Soil Moisture Density Test Method for Moisture Density Relations Classification of Soil for Engineering Purpose Particle Size Analysis of Soils
ASTM C136: ASTM D 3017:
ASTM D 1883: ASTM D 4253: ASTM D 4254: ASTM D 2937: ASTM D 698: ASTM D 2292: ASTM D 1557: ASTM D 2487: ASTM D 422:
Page 2 of 7
MACO-QCCP-003

Royal Commission Specifications: 02251 02220 02221 02210 02110 02220 Compaction and Testing of Earthwork Structure Excavation and Backfill Trenching, Bedding, Backfilling and Compacting Earth Work Clearing and Grubbing Structure Excavation & Backfill
Construction Specifications
Definitions None
5 5.1
Responsibilities The Civil Supervisor and/or Foreman are solely responsible for the activities related to Excavation, Trenching and Backfilling. They shall coordinate with the surveyor for the reference and with the QC Inspector and/or Independent Testing Laboratory Technician for inspection or testing requirements. The QC Inspector shall inspect and prepare RFI for Proponent representative to witness/inspect tests related to backfilling and compacting. He shall also coordinate with the surveyor on a daily basis to monitor and identify field changes. The Independent Testing Laboratory Technician shall be responsible for all necessary tests in the field. He shall also be responsible in recording all test results and generate reports of all tests conducted.
5.2
5.3
6 6.1
Procedure Surveying
Page 3 of 7
MACO-QCCP-003

6.1.1 Surveying shall be carried out in accordance to Work Procedure QCCP-001, Surveying. 6.2 Site Preparation 6.2.1 Earthworks shall be carried out in accordance with Work Procedure QCCP-002, Site Preparation. 6.3 Excavation/Trenching 6.3.1 Excavation/Trenching shall be performed as indicated on the plans and standard details in whatever material encountered. All excavations for structures, utility pipes, appurtenances or cables shall be made to an extent that will provide sufficient space to work conveniently around the structure or pipe to be installed. 6.3.2 All unsuitable surplus materials removed during excavation or trenching shall be removed from site and disposed of at a Government approved dump site. All materials suitable for backfill shall be used. 6.3.3 Excavation/Trenching over 1.2M deep shall be provided with sides sloped back to the natural repose of the soil to avoid caving. Sides which can not be sloped to the natural repose because of adjacent structures or ground condition shall be shored adequately to resist earth movement and protect workers. 6.3.4 If required for construction, before excavation, an approved dewatering system shall be installed and operated when necessary to lower the groundwater. All excavation and trenches shall be kept dry until the structures, pipes and appurtenances to be built are completed.
6.4
Structure Fill and Backfill 6.4.1 Compaction shall have a minimum of 70% relative density (ASTM D4253/4254) or 95% standard proctor density (ASTM D698) whichever is applicable and gives the greater density. 6.4.2 Fill and backfill under structures shall be select fill or coarse aggregate and fine aggregate when indicated or specified for use under structures, and conforming to requirements for coarse and fine aggregate. 6.4.3 Fill material shall be placed in lifts not exceeding 150 mm in thickness. Unless otherwise indicated or specified, each layer shall be compacted to 95% of the maximum density as determined by ASTM
Page 4 of 7
MACO-QCCP-003

D698 for cohesive material and within 1 % optimum moisture content or 70% relative density as determined by ASTM D 4253/4254 for cohesion less material. 6.4.4 Backfill against or on structures shall not be placed until they have attained sufficient strength to support the loads (including construction loads) to which they will be subjected, without distortion, cracking, or other damage. Special leak tests shall be provided, if required, as soon as practicable after structures are structurally adequate and other necessary work has been done. Backfilling shall be promptly started after completion of tests. Unequal soil pressure shall be avoided by depositing material evenly around structure. 6.4.5 The sides of all concrete foundations shall be primed and top coated with asphalt emulsion damp-proofing prior to backfilling. 6.5 Trench Backfill 6.5.1 The bottom of the trench shall be free of rock, sharp debris or foreign matter that could cause damage to pipes, cables or other new construction. 6.5.2 Cables or pipes shall be laid on a clean sand bed compacted to 70% relative density per ASTM D4253 and 4254. The bed shall be compacted uniformly to provide even bearing for pipes. After pipes have been laid, tested and approved; fillings shall be placed evenly on both sides of the pipes and periodically compacted to maintain equal pressure on the pipe. Backfilling shall be done in 150 mm lifts or half the pipe diameter whichever is greater until a depth of 300mm of fill over the pipe is obtained. 6.5.3 The depth of the trench shall be dug deep enough to provide a minimum ground cover above the top of the pipe and a ground bed of at least 150mm in depth below the bottom of the pipe. 6.5.4 Fill material shall be placed and built-up in successive layers and compacted by tamping, until it has reached the required elevation. Each layer shall be sloped to drain during construction. Layers shall not be allowed to exceed 200mm in thickness before compaction. Each layer of material shall be compacted by the use of rollers or other means so as to secure a dense, stable and thoroughly compacted mass. Where mobile mechanical equipment cannot be used, the materials shall be thoroughly compacted by the use of power driven tampers.
Page 5 of 7
MACO-QCCP-003

6.5.5 Cables or pipes shall be embedded all around with at least 150mm of compacted clean sand unless otherwise indicated, having minimum 70% relative density per ASTM D4253 and D4254.
6.6 Testing 6.6.1 In-place density test shall be performed in accordance with ASTM D1556, D2922 or D23167 after compaction of each lift to verify that the specified degree of compaction has been achieved. At least one in-place density test for every 90m2 of compacted soil shall be performed or for every layer or fill. Spacing between all test locations shall be approximately equal. 6.6.2 Should the work in question fail to meet the establish criteria for testing, remedial work shall be performed and re-tested to the satisfaction of the Proponent Representative.
6.7
Reinstatement 6.7.1 All trench excavations shall be restored so its surface contour blends in with the surrounding area. Areas of roadways and pavement shall be excavated as necessary and restored. 6.7.2 To install pipe, cable or conduits under existing pavement, pavement of the area shall be saw-cut as needed and restored to the original condition.
7 7.1
DOCUMENTATION Form QCCP-003-01-EP Excavation Checklist
Page 6 of 7
MACO-QCCP-003

EXCAVATION CHECKLIST QCCP-003-01-EP
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2 3 4 5 6 7
All backfilling layer should be as of indicated in the contract drawing. Select fill is of Clint Specification or as approved by the client. Do not allow layers to exceed 300mm in thickness before compaction. Compact each layers in accordance with Royal Commission for Jubail & Yanbus Standards. The bottom of the trench shall be free of sharp or loose rock, debris or foreign matter. Cable or pipe shall be laid on a 150mm thick clean sand bed. The bed should be compacted uniformly to provide even bearing for pipes.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Page 7 of 7
MACO-QCCP-003

DOCUMENT TITLE:
PROCEDURE FOR: ASPHALT CONCRETE PAVING & BASE COURSE

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Asphalt Concrete Paving and Base Course
Page 1 of 9
MACO-QCCP-004

ASPHALT CONCRETE PAVING AND BASE COURSE

1 Scope
1.1 This procedure includes, but is not limited to sub-grade preparation, aggregate base coarse, prime coat, tack coat, asphalt concrete paving, sampling and testing for the new construction of roads, driveways and parking areas as indicated in the Drawings. 2 Purpose
2.1 The purpose of this quality procedure is to provide a documented procedure for all activities related to Base Course application and construction of Asphalt Concrete Paving. 3 References
ASTM C88: ASTM C136: ASTM D1559: ASTM D1883: ASTM D2922: ASTM D4254: ASTM D4318:
Test Method for Sounding of Aggregate by Use of Sodium Sulfate or Magnesium Sulfate Test Method for Sieve Analysis of Fine and Course Aggregate Test Method for Resistance to Plastic Flow of Bituminous Mixture Test Method for CBR (California Bearing Ratio) of Laboratory Compacted Soil Test Method for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow Depth) Test Method for Maximum Index Density and Unit Weight of Soil and Calculation of Relative Density Test Method for Liquid Limit, Plastic Limit, and Plastic Index of Soil
Royal Commission Standards: 02555 Asphalt Concrete Pavement
Page 2 of 9
MACO-QCCP-004

Definitions Primer Coat Homogeneous, medium curing, liquid asphalt MC-70 conforming to Saudi Aramco Standards A973 or MC-250 conforming to Saudi Aramco Standard A974. Tack Coat Shall be RC 250 conforming to Saudi Aramco Standards A971 or RC-800, conforming to Saudi Aramco Standard A972.
5 5.1
Responsibilities The Civil Supervisor and/or Foreman are solely responsible for the activities related to Asphalt Concrete Paving. They shall coordinate with the QC Inspector for inspection or testing requirements. The QC Inspector shall inspect and prepare RFI for Proponent representative to witness/inspect tests related to Asphalt Concrete Paving. He shall also coordinate with the Independent Testing Laboratory Technician for inspection and testing requirements. The Independent Testing Laboratory Technician shall be responsible for all necessary tests in the field. He shall also be responsible in recording all test results and generate reports of all tests conducted. Procedure 6.1 General Requirements 6.1.1 Job-mix design shall be submitted to the Proponent Representative for approval prior to start of work, or shall combine the mineral aggregate and asphalt in such proportion as to produce a mixture conforming the client specification. 6.1.2 Earthwork shall be performed in accordance with Work Procedure QCCP-002, Site Preparation. 6.2 Sub-Grade 6.2.1 Existing asphalt or other materials identified to be demolished as shown on the drawings shall be removed prior to the commencement of sub-grade cut/fill. Asphalt shall be saw-cut to provide clean, neat vertical edges that will provide a suitable surface for matching of new asphalt.
5.2
5.3
Page 3 of 9
MACO-QCCP-004

6.2.2 Unless otherwise specified, sub-grade shall be compacted to 95% of the maximum dry density per ASTM D1557 or AASHTO T180 method D) while within 1.5% of the optimum moisture content or to 85% of relative density determined by ASTM D4253 and D4254. 6.2.3 All holes, ruts, soft places, and other defects shall be corrected. In no case shall the sub-base or base course be placed on soft or unstable material, or over areas that are not drained. 6.2.4 If the sub-grade is dusty or muddy, operations shall be delayed until it is in a condition satisfactory to the Proponent Representative. 6.2.5 Prior to delivery of materials for the base course, the road bed surface shall be prepared by sprinkling, blading, rolling and lightly scarifying where necessary, until the proper crown is obtained. When compacted and ready for base course construction, the road bed shall be well compacted, smooth hard and uniform, all irregularities having been bladed out and rolled smooth. 6.2.6 After the road bed has been prepared, it shall be maintained true to cross section and grade until the base course is completed. The road bed of the entire project shall be maintained from the time the work is started until covered with the base course. 6.2.7 The sub-grade shall be offered for inspection and approval by the Proponent Representative, prior to starting construction of the sub-base or base course on any portion of the work. 6.3 Base Course 6.3.1 The stone base course and sub-base shall be laid in two layers each and compacted. 6.3.2 Sub-base course shall be provided only in fill sections where fill material has a CBR of 5% or less. The sub-base shall have a minimum CBR of 15% at 95% compaction. 6.3.3 The sub-grade shall be kept drained during the placing and compacting of the base course or sub-base surface. 6.3.4 Base course material shall not be placed until the sub-grade upon which it is to be placed has been approved by Proponent Representative. Base course material shall be placed and compacted in layers not to exceed 150 mm thickness after compaction.
Page 4 of 9
MACO-QCCP-004

6.3.5 While at optimum moisture (1-%) the sub-base or base materials shall be compacted with equipment capable of obtaining the desired density to the full depth of the respective layer. The rolling shall continue until the base and sub-base are compacted to not less than (100% for the base and 95% for the sub-base) of the maximum laboratory dry density as determined by ASTM D1557, or AASHTO T180. In-place density shall be measured by ASTM D2922 or ASTM D1556 or other approved methods. Testing shall be conducted at a rate of one test every 2000 ft. (180m) of base or sub-base. 6.3.6 Following the construction of the aggregate base, the compacted base course shall be maintained by blading, brooming and otherwise maintaining the base, keeping it free from raveling, and other defects until such time as the bituminous prime coat or other surface is applied. Water shall be applied at such time and in such quantities as directed by the Proponent Representative. 6.4 Prime Coat Application: 6.4.1 The prime coat shall be applied and shall consist of the MC-70 conforming to the Saudi Aramco Standard A-973 or MC-250 conforming to Saudi Aramco Standard A-974. A prime coat shall consist of the initial application of liquid asphalt into the surface of non-asphalt base course. 6.4.2 Immediately before applying the primer bituminous material, the surface shall cleaned of all loose dirt and other objectionable materials with a power broom, hand broom, or blower. If so ordered by the Proponent Representative, the surface shall be lightly bladed and rolled immediately prior to the application of the bituminous material, in which case brooming or blowing will not be required. A light application of water shall be lightly applied, if required, just before the application of bituminous material. 6.4.3 Prime coat shall be applied only when the surface to be treated is dry and when the temperature in the shade is 8C and rising. Prime coat shall not be applied when the weather is foggy or rainy or in a sand storm. Bituminous material shall be applied by means of a distributor at a rate between 0.65 and 1.75 liters/M and at a temperature between 50C to 80C. If the material is applied in two lanes, there shall be an overlap of at least 200 mm. Any prescribed application may be divided in two applications to prevent plowing of the surface and additional bituminous material shall be applied where surface conditions indicate it is required. 6.4.4 The primed surface shall be kept free from all traffic and in a clean condition pending placement of the covering asphaltic concrete pavement.
Asphalt Concrete Paving and Base Course Page 5 of 9 MACO-QCCP-004

A minimum period of 24 hours shall be allowed for the absorption and curing of the prime coat prior to placement of covering pavement. 6.4.5 Surfaces of manhole cover and frames shall be coated with oil to prevent bond with asphalt pavement. These surfaces shall not be bonded with primer or tack coat.
6.5
Tack Coat Application: 6.5.1 The asphalt binder course shall be laid in two layers as per SAESQ-006. 6.5.2 The tack coat shall be of RC-250 conforming to Saudi Aramco Standard A-971 or RC-800, conforming to Saudi Aramco Standard A-972. 6.5.3 Tack coat shall be applied to all concrete surfaces that will be in contact with asphalt concrete pavement. Tack coat applications shall take place prior to the paving operations and will include contact surfaces of concrete gutters and other drainage structures. 6.5.4 Tack coat shall be applied between the binder course and the surface course; new and old asphalt surface, and vertical cut of adjacent to new asphalt. If application of the surface is delayed by more than 3 days, or if dirt, sand or other impurities have contaminated the tack coat, then a new tack coat shall be applied after the original one has been swept clean. 6.5.5 The bituminous material shall be applied on the binder course by means of a bituminous distributor at a maximum rate of 0.25 liters/M or as directed by the Proponent Representative. A hand broom shall be used for application of the tack coat to concrete surfaces not covered by the bituminous distributor. 6.5.6 Tack coat shall not be placed during rainy weather, or when the moisture on the surface to be paved would prevent proper bond. 6.5.7 Tack coat shall be applied to contact surfaces of curbs, gutters and berm walls.
6.6
Placement of Asphaltic Concrete 6.6.1 Asphalt shall be petroleum asphalt cement, Grade 60-70 penetration, conforming to Saudi Aramco Standard A-970.
Page 6 of 9
MACO-QCCP-004

6.6.2 Asphaltic concrete material shall not be accepted unless it is covered with tarpaulins until unloaded, and unless it has a temperature of at least 139C at the time of spreading and compaction.
6.6.3 Placement and compaction of the bituminous mixture shall progress in sections not more than 90M in length. The bituminous mixture shall be spread, shaped and finished with the power machine with automatic adjustable grade controlled by a ski or a straight line. The mixture shall be placed one-half width or one traffic lane at a time. After the first width has been compacted, the second width shall be placed, finished and compacted as specified for the first width. Asphaltic concrete shall not be placed when the atmosphere temperature is below 10C, nor during fog, rain, wind or other unsuitable conditions. 6.6.4 Asphaltic concrete material shall be spread in a manner which requires the least handling. When thickness of finished pavement will be 60 mm or less, material shall be spread in one layer. Maximum thickness of layer shall not exceed 120 mm in loose measurement. 6.6.5 After a layer has been placed the full width, the surface shall be rolled. Rolling shall be longitudinal, and shall commence at the outer edge of the road overlapping it and progress towards the center. Rolling shall continue until the surface is of uniform texture and degree of compaction is achieved, and is true to grade and cross section. Under no circumstances shall the center of the surface course be rolled first. 6.6.6 Asphalt Compaction Density requirement shall be equal to or greater than 96% of the Marshall Density of each day production per ASTM D1559. 6.7 Inspection and Testing: 6.7.1 In-place density test shall be performed in accordance with ASTM D1556, D2922 or D23167 after compaction of each lift to verify that the specified degree of compaction has been achieved. At least one in-place density test for every 90m2 of compacted soil shall be performed or for every layer or fill. Spacing between all test locations shall be approximately equal. 6.7.2 Should the work in question fail to meet the establish criteria for testing, remedial work shall be performed and re-tested to the satisfaction of the Proponent Representative. 6.8 Reinstatement

6.8.1 All trench excavations shall be restored so its surface contour blends in with the surrounding area. Areas of roadways and pavement shall be excavated as necessary and restored. 6.8.2 To install pipe, cable or conduits under existing pavement, pavement of the area shall be saw-cut as needed and restored to the original condition.
7 7.1
DOCUMENTATION Form QCCP-004-01-CP Base Course and Asphalt Concrete Paving Checklist
Page 8 of 9
MACO-QCCP-004

BASE COURSE & ASPHALT CONCRETE PAVING CHECKLIST QCCP-004-01-CP
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2 3 4 5 6 7
Sub-grade shall be compacted as per the client specification. Base course shall be compacted as per the client specification. Prime Coat shall be applied as per the client specification. Tack Coat shall be applied as per the client specification. Placement of Asphalt Concrete shall be applied as per the client specification. Thickness Tolerance: Measurement of any core shall not be deficiently by more than 10mm or 15% of the design thickness. Asphalt Concrete Mixture shall be applied as per the client specification.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Page 9 of 9
MACO-QCCP-004

DOCUMENT TITLE:
PROCEDURE FOR: CONCRETE WORKS

Index 1 2 3 4 5 6 7 Page Scope Purpose References Materials Procedure Inspection & Testing Documentation 2 2 2 2 4 10 10
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Concrete Works
Page 1 of 14
MACO-QCCP-005

CONCRETE WORKS
1 Scope 1.1 This document covers formworks, rebars, placing, finishing, curing and joints associated with construction of concrete structures. 2 Purpose 2.1 The purpose of this procedure is to describe the minimum requirements in construction of reinforced cement concrete work. 3 References
ACI 318
Building Code Requirements of Structural Concrete
Royal Commission Standards: 03348 Casts-In-Place Concrete
Materials: 4.1 Definitions: 4.1.1 Structural Concrete: All reinforced concrete including concrete with minimum reinforcement for temperature and shrinkage control. The 28 day design compressive strength (ASTM C39) shall be 35 MPa. or as required by design drawing. 4.1.2 Non-structural Concrete: Un-reinforced concrete of no significant structural value such as lean concrete for sub-slabs, mass concrete etc. The minimum 28 day compressive strength (ASTM C39) shall be 14 MPa. 4.2 Water: 4.2.1 Potable water shall be used in the production of concrete, placement of concrete, production of ice used in concrete operations, washing aggregates, cooling aggregates, curing concrete, and cleaning, wetting and cooling the forms.
Concrete Works
Page 2 of 14
MACO-QCCP-005

4.3
Cement: 4.3.1 Portland cement shall conform to ASTM C150, as specified by the client.
4.4
Aggregate: 4.4.1 Aggregates shall conform to ASTM C33. 4.4.2 Fine and coarse aggregate shall be considered as separate ingredients and combined gradation shall be the approved mix design. 4.4.3 Carbonate and dolomite materials shall not be permitted.
4.5
Admixtures: 4.5.1 Chemical admixtures shall conform to ASTM C494 and shall be used in accordance with manufacturers recommendations. The admixtures shall not reduce the strength of the concrete. 4.5.2 Silica Fume: Silica fume used as cement replacement shall be in accordance with ASTM C1240.
4.6
Reinforcing Steel: 4.6.1 Grade for fusion Bonded Epoxy Coated Rebars (FBECR) and Uncoated Rebars Reinforcement shall be new and to the following grades: General reinforcement shall be deformed billet steel conforming to ASTM A615/A615M, Grade 60 with a specified yield strength of 414 MPa. Welded steel wire fabric shall conform to ASTM A185 for plain fabric and to ASTM A497 for deformed fabric. Testing of tensile strength, bending and elongation in accordance with ASTM A370 for each diameter of reinforcing bars shall be done for every 200 tons of site delivered steel.
4.7
Curing Materials: 4.7.1 Hessian shall be in accordance with AASHTO M182 and shall weigh 0.29 kg/m2.
Concrete Works
Page 3 of 14
MACO-QCCP-005

4.7.2 Impervious Sheeting shall be polyethylene, and in accordance with ASTM C171. 4.8 Colored Concrete: 4.8.1 Concrete used for underground duct encasement shall have a minimum compressive strength of 20 MPa. As required by design drawing. Aggregate size shall be as per concrete mix design. 4.8.2 Concrete encasement for underground electrical ducts shall be colored red by adding 1 Kg. of red oxide powder per 100 Kg. of cement. 4.9 Accessories: 4.9.1 All sleeves, inserts, anchor bolts, water stops and other embedded items shall be installed in accordance with the design drawings and supported against displacement. 4.9.2 The coating materials in accordance with the coating system specifications shall be used. 4.9.3 For critical applications, coating materials from clientapproved manufacturers shall only be used. 4.9.4 The type of abrasive to be used shall be determined by the degree, of cleanliness and roughness required for the coating system. Abrasives commonly used are sand, garnet and grit.
Procedure 5.1 GENERAL: 5.1.1 All structural concrete shall be planned mix. Client shall approve batching plant and the design of the concrete mix to be used. 5.1.2 All plant facilities are subject to random inspection for compliance with the approved design mix. 5.1.3 The mix design will encompass: Compressive Strength Cement Content and Type
Concrete Works
Page 4 of 14
MACO-QCCP-005

Fine and Coarse Aggregates Water Cement Ratio Air Content Slump Admixtures if any. 5.2 FORM WORKS: 5.2.1 Comply with provisions of ACI 347-78 Recommended Practice for Concrete Formwork for design and construction. 5.2.2 Formwork will be inspected for the following: Dimensional Accuracy as per drawings. Line and level with tolerances. Metal embeds and inserts are at accurate positions. Firmness of forms and supports. Form surfaces must be clean and coated with approved form release agent. Chamfer strips to be used on exposed corners. Inside of forms must be cleared of all debris before placing concrete. Install and properly tighten all form ties or clamps as specified. All threads should fully engage the nut or coupling. 5.3 REINFORCEMENT: 5.3.1 All reinforcement fabrication shall be carried out by qualified craftsmen. 5.3.2 Epoxy coated rebars shall be bent using fiber or plastic mandrels to prevent damage to coatings. 5.3.3 Any damage coating shall be repaired using epoxy touch up paint kit. 5.3.4 Place reinforcement as per correct size and spacing. Position, support and secure reinforcement against displacement using pre-cast concrete blocks or PVC chairs. 5.3.5 Minimum bend diameter shall be as per the table below (Refer to Table 7.2 of ACI 318)
Concrete Works
Page 5 of 14
MACO-QCCP-005

Rebar Size 10 mm to 25 mm Dia. 28 mm to 36 mm Dia. 43 mm to 57 mm Dia.
Minimum Dia. Of Bend 6 times diameter of bar. 8 times diameter of bar. 10 times diameter of bar.
5.3.6 Adequate cover over reinforcement as required by codes is needed for protection of steel and long term durability of the concrete. The following minimum concrete cover shall be provided for reinforcement, unless otherwise shown in the construction drawings:
DESCRIPTION COVER INCH
a b
Clear cover concrete in contact with soil (all Substructures.) Concrete exposed to weather: i) 18mm to 57mm dia. bar ii) 16mm and below Concrete not exposed to weather or in contact with ground: i) Slab, wall and joists 43 to 57mm 36mm and below ii) Beam and Column: Primary reinforcement, ties, stirrups, spirals. iii) Shells, folded plate numbers 18mm dia. and more 16mm dia. and lower
3 in. 2 in. 1-1/2 in.
1-1/2 in. in. 1-1/2 in. in. in.
5.3.7 Minimum splice length shall be as shown on the drawings. 5.3.8 Hooks and bends, including minimum extensions, shall be made in accordance with the approved shop drawings. 5.3.9 When rebar details are shown on the design drawing marked Issued for Construction the reinforcing steel shall be fabricated in accordance with these schedules. 5.3.10 Reinforcing steel, at the time of placing in the forms and prior to concrete pour, shall be free from mud, oil, or other deleterious coatings that will reduce the bond.
Concrete Works
Page 6 of 14
MACO-QCCP-005

5.3.11 Welding of crossing bars shall not be permitted for assembly of reinforcement unless authorized by the client. 5.3.12 Handling and fabrication of epoxy coated reinforcement shall be in accordance with ASTM A775 Appendix and concrete reinforcing steel. 5.4 CONCRETE PLACING: 5.4.1 Concrete placement is accomplished with buckets, hoppers, chutes, drop pipes, conveyor belts or pumps as required, in accordance with ACI304-R. 5.4.2 All structural concrete shall pour over lean concrete along with vapor barrier. 5.4.3 Deposit concrete continuously and at such a rate that the underlying concrete is still plastic. 5.4.4 The method of holding water stop in the forms should ensure that it cannot bend to form cavities during concreting. 5.4.5 Bars and embedded items should be held securely in the proper position by suitable supports and ties to prevent displacement during concreting. 5.4.6 Ensure proper vibration. Over vibration should be avoided to prevent segregation. 5.4.7 Vibrators are not to be used to transfer concrete inside forms. Any movement of concrete is to be by hand shovel. Re-tempering of concrete is not allowed. 5.4.8 Vertical drop of concrete shall not exceed 1.5 meters. 5.4.9 Dampen the sub-grade and forms to prevent moisture loss at the base of the slab prior to pouring. 5.5 HOT WEATHER CONCRETING: 5.5.1 Hot weather may lead to problems in mixing, placing and curing hydraulic cement concrete that can adversely affect the properties and serviceability of the concrete. Most of these problems relate to the increase rate of cement hydration at higher temperature and the increase evaporation rate of moisture from the freshly mixed concrete. The rate of cement hydration is dependent upon concrete temperature, cement
Concrete Works Page 7 of 14 MACO-QCCP-005

composition and fineness, and admixtures used. Preparations and procedures are required to reduce the undesirable effects of hot weather concreting in general type of construction. Generally, if concrete strengths are satisfactory and curing practices are sufficient to avoid undesirable drying of surfaces, durability of hot weather concrete should not be greatly different from similar concrete placed at normal temperature. 5.5.2 The following list of practices and measures to reduce or avoid the potential problems of hot weather concreting: Use concrete materials and proportions with satisfactory records in field use under hot weather conditions. Use cool concrete. Use a concrete consistency that permits rapid placement and effective consolidation. Transport, place, consolidate and finish concrete with least delay. Plan the job to avoid adverse exposure of the concrete to the environment; schedule placing operations during times of the day or night when weather conditions are favorable. Protect the concrete against moisture loss at all times during placing and during its curing period. Protect freshly placed concrete from premature drying. 5.6 CONCRETE CURING AND PROTECTION: 5.6.1 Protect freshly placed concrete from premature drying. In extremely dry and hot weather, fogging of the surrounding area may be required. 5.6.2 Water for curing shall be sweet water. 5.6.3 Start curing as soon as the concrete surface has hardened sufficiently. Curing of concrete shall strictly continue as per ACI/RC Specifications. 5.6.4 A plasticized sheet vapor barrier shall be placed beneath slabs on grade. Outdoor sidewalks are exempted from this requirement. 5.6.5 A plasticized sheet vapor barrier or lean concrete shall be placed beneath concrete foundations. Lean concrete thickness shall be as per conceptual drawings/scope of work. i.e. 100mm. 5.6.6 All concrete surfaces in direct contact with earth shall be coated with two (2) coats of coal.
Concrete Works
Page 8 of 14
MACO-QCCP-005

5.7
JOINTS: 5.7.1 Construction Joint: Locate construction joint as per design drawings. Pattern of reinforcement for construction joint and other joints shall be submitted to Proponent for approval. Unless otherwise specified, the surface of the previously placed concrete shall be prepared by exposing aggregate and removing laitance, loose particles. And damaged concrete. Immediately before placing new concrete, the joint surface shall be thoroughly saturated and excess surface water shall be removed. Reinforcing steel and mesh shall be continued across construction joints. 5.7.2 CONSTRUCTION JOINT: Construction joints shall be by saw cutting and location shall be as per design drawings. Start cutting as soon as concrete has hardened sufficiently to prevent dislodgement of aggregates. Saw a continuous slot to a depth of one-fourth the thickness of the slab. 5.7.3 EXPANSION JOINT: General: Width of joints shall be (13 mm) minimum and 1 (25 mm) maximum. Sides of joints shall be parallel. Joints in paving areas shall be spaced not more than 15 meters (50 ft). Reinforcing Steel: Reinforcing Steel shall not extend through joints. Dowels shall be bonded on only one side of the joint. Water stop shall extend through the joint whenever required. Sealer Application: Non-process Areas: Sealer shall be applied as per the manufacturers recommendations. Process Areas: Joint surfaces shall be thoroughly cleaned to remove curing compounds, laitance, sand and dust etc.
Concrete Works
Page 9 of 14
MACO-QCCP-005

A plastic foam backer shall be inserted in to the joint to provide a depth as per the manufacturers recommendations. Sealer shall be mixed and applied as per the manufacturers recommendations.
6 6.1
INSPECTION AND TESTING: Services of client approved third party testing agency shall be utilized for testing. Perform all tests and inspection in accordance with the client specifications and ITPs.
6.2
6.3 Independent Testing Laboratory shall be employed to perform field and laboratory testing which shall include compressive tests of molded concrete cylinder tests, slump, unit weight, air content (where air entrapment is required) and fresh concrete temperature. The minimum required number of concrete tests cylinders for strength tests shall be 3, for 3,7 and 28 days.
7 7.1
DOCUMENTATION Concrete Work Checklist QCCP-005-01-CW QCCP-005-02-CW QCCP-005-03-CW
7.2 Concrete Request Form 7.3 7.4 Concrete Slump Test Form Concrete Compressive Strength Test Form
QCCP-005-04-CW
Concrete Works
Page 10 of 14
MACO-QCCP-005

CONCRETE POURING CHECKLIST QCCP-005-01-CW
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2 3 4 5 6 7 8
Concrete mix shall be as per the client specification or as approved by client representative. Test sample shall be taken as per the client specification and requirement. Set form to the required grade, lines, rigidly braced and secure. Anchor bolt size, type and location. Provide expansion/Contraction joint as shown in the drawing. Locate, place and support reinforcement as per the drawing details and specifications. Ensure proper placement and vibration. Perform concrete finishing as required by the client.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

MACO SUPERVISOR Proponent REPRESENTATIVE
CONCRETE REQUEST FORM

Concrete Works Page 11 of 14 MACO-QCCP-005

QCCP-005-02-CW
Time & Date of Pour: _________________ Project: _______________________
Drawing No: _________________________
CONCRETE TYPE 2000 psi 4000 psi OTHERS 100 125 150 175 200
SLUMP REQUIRED Blind
CONCRETE FOR:
Cable Box/Man Hole Paving Walls Pedestal RCC Structure
SIZE OF FORM WORK NOS. LENGTH BREADTH HEIGHT QUANTITY (M)
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

Concrete Works
Page 12 of 14
MACO-QCCP-005

SLUMP & TEMPERATURE TEST REPORT QCCP-005-03-CW
Date: Project: Sample No. Tested By:
_______________________ _______________________ _______________________ _______________________
Drawing No: _________________________ Sample By: ___________________________
TEST NO.
TRUCK/TICKET NO.
TIME BATCHED HR.
TIME SAMPLED HR.
MAX. TEMP. 0C
SLUMP
REMARKS
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
______________________ SOURCE OF CONCRETE:

MACO SUPERVISOR
___________________________ INDEPENDENT TESTING LAB.

Concrete Works
Page 13 of 14
MACO-QCCP-005

COMPRESSIVE TEST REPORT QCCP-005-04-CW
Date: Project: Sample No. Tested By:
_______________________ _______________________ _______________________ _______________________
Drawing No: _________________________ Sample By: ___________________________
TRUCK/TICKET NO.
TIME BATCHED HR.
TIME SAMPLED HR.
AIR CONTENT %
MIX TEMP. 0 C
CURING TEMP. 0C
AIR TEMP. 0 C
SLUMP
AGE(DAYS) DIMENSION SL# mm
TEST DATE AREA mm2 WEIGHT g DENSITY Kg/m3 DIAL Kn

COMPRESSIVE STRENGTH
Kg/cm2
Psi
MPa
REMARKS

Kg/cm2
Psi
MPa
REMARKS

Kg/cm2
Psi
MPa
REMARKS
Concrete Works
Page 14 of 14
MACO-QCCP-005

DOCUMENT TITLE:
PROCEDURE FOR: GROUTING WORK

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Grouting Works
Page 1 of 6
MACO-QCCP-006

GROUTING WORKS
1 Scope 1.1 This document covers the installation of: Cement Based, Non-Shrink Grout Epoxy Grout 2 Purpose 2.1 The purpose of this procedure is intended to describe the minimum requirement for structural and Equipment Grouting. 3 References
ASTM C307
Test Method for Tensile Strength of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing Test Method for Absorption of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing Test Method for Static Modulus of Elasticity and Poisons Ratio of Concrete in Compression Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing Test Method for Compressive Strength of ChemicalResistant Mortars, Grouts, and Monolithic Surfacing and Polymer Concrete Test Method for Flexural Strength and Modulus of Elasticity of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacing and Polymer Concrete Test Method for Compressive Creep of Chemical-Resistant Polymer Machinery Grouts
ASTM C413
ASTM C469
ASTM C531
ASTM C579
ASTM C580
ASTM C4318
Grouting Works
Page 2 of 6
MACO-QCCP-006

Royal Commission Standards:
GES-013-56
Grouting of Foundation
Materials: 4.1 General Requirements: 4.1.1 Cement Based Non-Shrink Grout and Epoxy Grout for Structural and Equipment Grouting shall be as per Royal Commission for Jubail & Yanbu specifications. 4.1.2 Submit manufacturers catalogue to Royal Commission for Jubail & Yanbu representative for approval before placing order for materials. 4.1.3 Resin component shall consist of premeasured, prepackaged, solvent free, epoxy resin specifically formulated for the used grout system. 4.1.4 The hardener component shall consist of a premeasured, prepackaged liquid specifically formulated to produce the specified final properties when mixed with the other component. 4.1.5 The aggregate shall be premeasured, prepackaged blend of inert, inorganic fillers, such as silica, designed specifically to provide the proper flow, handling and physical properties required for the grout product. 4.2 Handling: 4.2.1 Deliver all materials such as resin, hardening component and other admixture to the job site in original containers. 4.2.2 Keep stored material covered and protected.
Procedure 5.1 General: 5.1.1 All grouting work shall be done as per the drawing details and Royal Commission for Jubail & Yanbu Specifications.
Grouting Works
Page 3 of 6
MACO-QCCP-006

5.1.2 Epoxy grout shall be installed as per the manufacturers data sheet. 5.1.3 The epoxy grout manufacturers recommendations on maximum depth of pour and length to width ratio shall be followed. 5.1.4 If the grout pour is 100 mm or deeper, the grout manufacturer recommendation for installing reinforcement rebar shall be followed. 5.1.5 Safety requirements specified in the grout manufacturers data sheets shall be followed while application of grout system. 5.1.6 The ratio of aggregate to resin and hardener shall be as per the manufacturers recommendations. 5.1.7 When type of grout is not specified by Royal Commission for Jubail & Yanbu, or by the equipment Manufacturer, Cementitious grout shall be used for any of the following: i) For Rotating Equipment that satisfies all of these requirement: Driver horsepower less than 500 (373KW). 3600 RPM or less. Combined weight of machine, driver and base plate up to 2,200 Kg. (5,000 Lbs.) ii) Grouting for structural base plates, anchor bolts, columns and precast members, i.e. wall panels beams etc.
5.1.8 When type of grout is not specified by Royal Commission for Jubail & Yanbu or by the equipment manufacturer, epoxy grout shall be used for any of the following: Equipment with driver horsepower 500 (373 Kw). Equipment with speed greater than 3600 RPM. Equipment that has a combined weight (Machine, driver and base plate) of greater than 2,270 Kg. (5000 Lbs.). All reciprocating machinery with driver horsepower greater than 50 (37KW). 5.1.9 Cementitious grout shall be cured with potable water for a minimum period of seven days.
INSPECTION AND TESTING:
Grouting Works
Page 4 of 6
MACO-QCCP-006

6.1 Ensure grouting is as per the drawing details and specifications. 6.2 Follow the maximum depth of pour and length to width ratio is as per manufacturers recommendations. 6.3 Follow the safety requirements specified in the grout manufacturers data sheets. 6.4 If the grout pour is 100mm or deeper, install reinforcement as per manufacturers recommendations. 6.5 The ratio of aggregate to resin and hardener shall be as per the manufacturers recommendations.
7 7.1
DOCUMENTATION Grouting Checklist QCCP-006-01-GW
Grouting Works
Page 5 of 6
MACO-QCCP-006

GROUTING CHECKLIST QCCP-006-01-CW
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2
Ensure grouting is as per the drawing details and Specifications. Follow the maximum depth of pour and length to width ratio is as per manufacturers recommendations. If the grout pour is 100mm or deeper, install reinforcement as per manufacturer recommendation. The ratio of aggregate to resin and hardener shall be as per the manufacturers recommendations.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Grouting Works
Page 6 of 6
MACO-QCCP-006

DOCUMENT TITLE:
PROCEDURE FOR: PROTECTIVE COATING FOR BURIED CONCRETE

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Protective Coating for Buried Concrete
Page 1 of 5
MACO-QCCP-007

PROTECTIVE COATING FOR BURIED CONCRETE

1 Scope: 1.1 This section covers the requirement for materials and application procedure for the following works: Surface preparations for buried concrete surfaces. Coating application for buried concrete surfaces. 2 Purpose: 2.1 This procedure is intended to describe the minimum requirements for surface preparation, Coating application for Buried concrete surfaces. 3 References and Standards:
ASTM D 4263
Standard Test Method for Indicating Moisture in Concrete by the Plastic Sheet Method. Standard Test Method for Indicating Oil or Water in Compressed Air. Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers. Standard Test Method for Measuring Humidity with a Psychrometer
ASTM D 4285
ASTM D 4541
ASTM E 337
Royal Commission Standards:
09874
Protective Coating and Lining System
Materials: 4.1 General Requirements: Client approved Coating system specifications or equivalent shall be used.
Page 2 of 5
MACO-QCCP-007

4.2
Paint manufacturers: Unless otherwise specified, manufacturer mentioned below shall be preferred. 4.2.1 Hempel Industrial Coatings. P.O. Box 1077 Dammam 4.2.2 Sigma Paints P.O. Box 7509 Dammam 4.2.3 Saudi Industrial Paint Co. P.O. Box 2549 Riyadh 4.2.4 Arabian Danish Co. Ltd. 4.2.5 Jotun Saudia Co. Ltd.
5 5.1
Procedure: Preparation of Surface: 5.1.1 New concrete shall be allowed to cure for a minimum of 7 days prior to coating or as per client requirement. 5.1.2 Perform preparation and cleaning procedures in accordance with paint manufacturers instructions. 5.1.3 For old concrete surface remove oil and greases by mechanical cleaning. 5.1.4 For old concrete surface remove all loose concrete, sealants and ols coating by abrasive blasting. 5.1.5 In the case of coating for old concrete surfaces any cracks found should be prepared as per the concrete repairing procedure. 5.1.6 Expansion and construction joints, if they are to be removed, be cleaned out and masked off prior to coating. If they are not to be removed, then they must be masked off. When all coating is complete, remove the masking and replace with new sealant as required. 5.2 Application: 5.2.1 All filling and coating must be done after sealing. 5.2.2 All below grade concrete surfaces (except the bottom) shall be coated with Bitumastic 300M by Kop-Coat. The coating shall be applied per the manufacturers instructions after the concrete is a minimum of
Page 3 of 5
MACO-QCCP-007

seven days old. The dry film thickness of the coating shall be a minimum of 0.4 mm (16 mils). Coating of vertical surfaces shall extend to 150 mm (6 inches) above grade. 5.2.3 Finishing coats shall be applied according to the manufacturers data sheet, taking into consideration the spreading rate requirement. 5.2.4 Any visual pin holes and cracks shall be repaired. 5.2.5 Comply with the recommendations of the product time gap between succeeding coatings. 5.2.6 Keep brushes and spraying equipment, clean, dry, and free from contaminants. 5.2.7 Keep brushes and spraying equipment suitable for the finish required. 5.2.8 Do not apply additional coats until the previous completed coat has been approved by the client representative. 5.2.9 Provide wet paint signs required to protect newly-painted finishes.
INSPECTION AND TESTING: 6.1 Inspection and Testing shall be performed in accordance with ITP and client specifications.
7 7.1
DOCUMENTATION Protective Coating for Buried Concrete Checklist QCCP-007-01-BC
Page 4 of 5
MACO-QCCP-007

PROTECTIVE COATING FOR BURIED CONCRETE CHECKLIST QCCP-007-01-BC
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2 3
Only approved products shall be used. Perform preparation and cleaning procedures in accordance with paint manufacturers instructions. Examine surfaces scheduled to receive paint and finishes for conditions that will adversely affect execution. Protect all the hardware accessories, machined surfaces, plates etc., prior to surface preparation and painting operation. For old concrete surface, remove all loose concrete, oil, grease and other contaminants sealants and old coating. Expansion and construction joints, if they are to be removed be cleaned out and masked off prior to coating. Cracks and holes shall be repaired as per old concrete repairing procedure. Previous completed coat has been approved.
4 5 6 7 8
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

Page 5 of 5
MACO-QCCP-007

DOCUMENT TITLE:
PROCEDURE FOR: WATERPROOFING, CAULKING AND SEALING

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Waterproofing, Caulking and Sealing
Page 1 of 6
MACO-QCCP-008

WATERPROOFING, CAULKING AND SEALING

1 Scope: 1.1 This section covers installation of: Water Proofing. Caulking and Sealing. 2 Purpose: 2.1 This procedure is intended to describe the minimum requirements for water proofing system. 3 References and Standards:
ASTM C 156
Test Method for Water Retention by Concrete Curing Materials Standard Specification for Elastomeric Joint Sealant Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers. Test Method for Water Vapor Transmission of Materials
ASTM C 920 ASTM E 96
ASTM E 337
Royal Commission Standards: 07110 Membrane Water Proofing of Underground Concrete Structures
Materials: 4.1 General Requirements: 4.1.1 Waterproofing: Membrane shall be preformed, cold applied, self adhesive, laminated sheet membrane or as per the client specifications.
Page 2 of 6
MACO-QCCP-008

4.1.2 Caulking: The compound shall be elastomeric, single or multi-component, non-sag, paintable, and have zero moisture/vapor permeability or as per the client specification. 4.1.3 A ready mixed sealant shall have a consistency suitable for easy mixing with a light hand mixer and easy application by a manual or an air operated gun in a temperature range of 50C to 500C or as per the client specifications. 4.1.4 If required, Manufacturers approved primer shall be provided with the sealant. 4.1.5 Bound Breakers: Polyethylene tapes or as recommended by the sealant manufacturer or as per the client specifications. 4.1.6 Vapor Barrier: 8-Mil polyethylene sheeting, having an ASTM E 96 vapor permanence not exceeding 0.50 per m and having ASTM C 156 loss water not exceeding 0.055 g/cm2 of structure or as per the client specifications. 4.1.7 Vapor Barrier Joint Sealant: Hot or cold applied mastic or plastic cement provided by sheeting manufacturer or as per the client specifications. 4.2 Manufacturers: Manufacturer shall be as per the client specifications. Unless otherwise specified, manufacturer mentioned below shall be preferred. 4.2.1 Fosam Company Ltd. Dammam 4.2.2 Saudi Industrial Company Ltd. Dammam 4.3 Handling: 4.3.1 Deliver materials in original, unopened packages bearing name of the manufacturer and product identification. 4.3.2 Store materials above the ground, under covered area. 5 Procedure: 5.1 General: 5.1.1 Waterproofing, Caulking and Sealing shall be done as indicated in the drawing details and client specifications.
Waterproofing, Caulking and Sealing Page 3 of 6 MACO-QCCP-008

5.1.2 Unless otherwise indicated in general use: Sealants in Joints exposed to exterior. Caulking in joints exposed to interior. Caulk and seal joints between frames in masonry opening and the masonry in or against which they are set. 5.2 Preparation: 5.2.1 Waterproofing: Ensure the surfaces are clean, dry and free from dust and dirt, and otherwise prepared as recommended by the material manufacturer. 5.2.2 Caulking and Sealant: Ensure that surfaces and joint cavities are clean, dry and free from loose particles, oil, grease, asphalt tar, dirt, rust and other materials that may result in the loss of bond. 5.3 Application: 5.3.1 Caulking: Apply caulking as recommended by the sealant manufacturer or as per the client specifications. 5.3.2 Tool caulking smooth, free from wrinkles and sufficiently convex to result in flush finish joint when dry. 5.3.3 Sealant: Apply in accordance with manufacturers printed instructions regarding mixing, surface preparation, application life and application procedure. 5.3.4 Prime concrete, masonry, wood and other porous surface. 5.3.5 Mask finish surfaces on both sides of the joint cavities to protect from sealant smears. Remove masking after joints are sealed and tooled. 5.3.6 Fluid Applied Waterproofing: Apply in accordance with manufacturers printed installation specifications. Thin first coat.
Page 4 of 6
MACO-QCCP-008

Apply second coat to produce a minimum dry fill thickness of 10 mils. 5.3.7 Vapor Barrier: Place polyethylene sheeting as indicated in drawing. Lap sheet 150 mm (6 in.) with the top sheet placed in the direction of concrete placement. Turn sheeting up at the walls and seal all lap joints.
6 6.1
INSPECTION AND TESTING: Perform inspection and testing in accordance with client approved ITP and client specifications.
7 7.1
DOCUMENTATION Water Proofing, Caulking & Sealing Checklist QCCP-008-01-WP
Page 5 of 6
MACO-QCCP-008

WATERPROOFING, CAULKING AND SEALING CHECKLIST QCCP-008-01-WP
Reference: Project:
_______________________ _______________________
Drawing No: _________________________
S. NO.
INSPECTION POINTS
ACCEPT
REJECT
N/A
1 2 3
Only approved products shall be used. Perform preparation and cleaning procedures in accordance with sealant manufacturers instructions. Examine surfaces scheduled to receive sealant and finishes for conditions that will adversely affect execution. Surfaces and joint cavities are clean, dry and free from loose particles, oil, grease, asphalt tar, dirt, rust and other materials that may result in the loss of bond. Tool caulking smooth, free from wrinkles and sufficiently convex to result in flush finish joint when dry.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Page 6 of 6
MACO-QCCP-008

DOCUMENT TITLE:
PROCEDURE FOR: NON-METALLIC PIPES INSTALLATION (GRP PIPES)

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Non-Metallic Pipes Installation
Page 1 of 6
MACO-QCCP-009

NON-METALLIC PIPES INSTALLATION

1 Scope: 1.1 This section covers installation of all types of non-metallic piping. 2 Purpose: 2.1 The purpose of this procedure is to define and establish necessary requirement for successful installation of non-metallic piping for industrial, commercial facilities and buildings. 3 References and Standards:
ASME B31.3 AWWA C950 UPC
Chemical Plant and Petroleum Piping Fiber Glass Pressure Pipe Uniform Plumbing Code
Royal Commission Standards: 2650 2722 Underground Piping Sewage Systems
Materials: 4.1 The piping materials and fittings manufactured in accordance to the ratings and specifications as specified in the scope or by the client.
Procedure: The following procedures shall be adopted as per the requirements: 5.1 Storage and Handling: 5.1.1 Pipe shall be stored out of direct sunlight in a building or under a cover that allows free air circulation.
Page 2 of 6
MACO-QCCP-009

5.1.2 Racks shall confirm to factory shipping packages for each pipe size. Shelves shall be provided for continuous support of the pipe. 5.1.3 If the loose pipes are stacked on each other, the stack height shall not exceed 1.5m. Adequate side support shall be provided to prevent slipping or rolling. 5.1.4 If pipe is stored on racks or bearing boards, the supports shall be at least 75mm wide. Supports shall be spaced on 3m centers maximum with first supports 1.5m from the end of the pipe. 5.1.5 All supporting surfaces shall be free of sharp objects. 5.1.6 Thermoplastic and GRP (Glass Fiber Reinforced Pipe) fittings shall be stored in a building or under a cover that allows free air circulation. 5.1.7 Solvent cement and primer for thermoplastic piping shall be stored in an air-conditioned building with a maximum temperature of 26.7 Deg. Centigrade or as specified by the manufacturer. 5.1.8 Gaskets, O-rings, and locking keys shall be stored flat on racks below 38 0C and out of direct sunlight or as specified by the manufacturer. 5.1.9 Adhesive for GRP piping shall be stored in an enclosure where temperatures do not exceed 38 0C or as specified by the manufacturer. 5.1.10 Pipe and fittings shall be properly protected from impact, especially on their ends. They shall not be thrown, dropped, bumped, hit or dragged and pushed over abrasive surfaces. 5.1.11 Loose thermoplastic or GRP pipe shall be handled by hand or, if the pipe is too heavy, use nylon or cotton strap spreader slings. 5.1.12 Adhesive and solvent cement containers shall be tightly closed when not in use, and shall be returned to the storage facilities to minimized exposure to excessive temperature. 5.1.13 Thermoplastic pipe shall have continuous support along its entire length when being transported by either truck or pipe trailer. All sharp edges that could touch the pipe shall be padded with sacks, rubber strips or other suitable material.
5.1.14 Bearing boards at least 75 mm. wide shall be used to protect GRP pipe from sharp objects on the truck beds. Rubber tire sections or other
Non-Metallic Pipes Installation Page 3 of 6 MACO-QCCP-009

suitable material shall be attached to the bearing boards. Support spacing and height limits shall be followed as specified above, except that the end support shall not be more than 1m from ends of the pipe. 5.1.15 Thermoplastic and GRP pipes shall be secured with cotton or nylon straps. 5.1.16 Solvent cement primer and adhesive containers shall be protected from direct sunlight. 5.2 Inspection Prior To Installation: 5.2.1 Each piece of pipe and fittings shall be examined for cuts, scratches, gouges, kinks, buckles and ultra-violet (sun) damage. Damaged lengths of pipe shall be cut out and discarded. Damage fittings shall be discarded. GRP Pipes and fittings which show ultra-violet damage and weathering effects shall not be used. 5.2.2 All GRP pipes and fittings shall be visually inspected for scratches, damaged ends, cracks, de-lamination, crushing, weathering and cracked O-rings and gaskets. Damaged pipes and fittings shall not be used. 5.2.3 Pipe and fittings shall be cleaned before installation. 5.2.4 Any primer, solvent cement, or adhesive that is beyond the stamped expiration date shall be discarded. Solvent cement that has gelled or thickened shall be discarded. Leaking or opened containers shall also be discarded. 5.3 Underground GRP Piping Installation: 5.3.1 For Underground pipe installation, follow attached AMIANTITS GUIDE for installing underground pipe.
INSPECTION AND TESTING: Following tests are applicable depending upon the requirements: 6.1 Hydrotest.
6.2 Unless prevailing conditions or regulations require full backfilling of the piping prior to the hydrotest, under ground piping shall be partially backfilled with all joints exposed during the hydrotest. The exposed joints shall be shaded from direct sunlight, and the hydrotest shall be performed so that the
Non-Metallic Pipes Installation Page 4 of 6 MACO-QCCP-009

temperature of the piping material or temperature of the test water does not exceed 40 0C during the test period. 6.3 Potable water (Drinking and raw water) piping systems shall be hydrotested with fresh potable water. 6.4 No adhesive-bonded GRP piping shall be pressurized until it has cured in accordance with the manufacturers instructions. 6.5 The test pump shall be placed on firm ground away from the piping. The pump and the piping system (piping and equipment) shall be protected from over pressure by relief valves of adequate capacity set at 5% above the test pressure or a maximum of 170 KPa (25Psig) above the test pressure for pressure piping systems. The relief valve shall be tested, dated and tagged. Sizing of relief valve used for testing shall be in accordance to the specifications. 6.6 Requirements of pressure gauges and pressure recorders for pressure piping systems, calibration intervals, and calibration certificates shall be in accordance with the client specification. Calibrated and tagged relief valves may be used as the pressure test instrument upon approval by client. 6.7 The lines whose joints have been backfilled shall be tested as specified by the client at the following pressures for 24 hours. Lines whose joints have not been backfilled or are above the ground shall be tested at the following pressures for 4 hours: 1035KPa (150Psig) or 345 KPa (50 Psig) above the operating pressure, whichever is greater. 6.8 During hydrotest, all exposed pipe joints fittings, valves and hydrants shall be carefully examined for leakage. 6.9 Leaking pipes, joints and fittings shall be replaced.
6.10 The hydrostatic test shall be repeated after the repair of any defects until the system is proved satisfactory. 6.11 The piping shall be satisfactory if there is no evidence of leakage or pressure loss after the specified test period.
7 7.1
DOCUMENTATION Non-Metallic Piping (GRP) Installation Checklist

Page 5 of 6
QCCP-009-01-PI
MACO-QCCP-009

NON-METALLIC PIPING (GRP) INSTALLATION CHECKLIST QCCP-008-01-WP
Reference: Project:
_______________________ _______________________
Drawing No: _________________________

S. NO. INSPECTION POINTS ACCEPT REJECT N/A
1 2 3 4 5 6 7 8 9 10 11 12
Visual inspection for pipe fittings. Is pipe fitting cleaned before installation? Is ground prepared with sand bed? Is trench continuous? Is trench smooth? Is trench free of rocks? Is necessary shoring provided? Are sleeves installed in the road crossings? Are fittings, valves and joints accepted? In trench, is thrust block provided? Is backfilling and pavement completed as per the requirement? Is hydrotest successfully completed?
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Page 6 of 6
MACO-QCCP-009

DOCUMENT TITLE:
PROCEDURE FOR: CONCRETE BATCH PLANT

Index 1 2 3 4 5 6 7 Purpose Scope References Definitions Responsibilities Procedure Documentation Page 2 2 2 2 2 3 9
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Concrete Batch Plant
Page 1 of 4
MACO-QCCP-010

CONCRETE BATCH PLANT

1.0 SCOPE This procedure covers all activities pertaining to Batch Plant Management and Inspection before and during production of concrete at the Batch Plant. 2.0 PURPOSE The quality control procedure has been developed in order to highlight the operation and performance of the batch plant in accordance with the quality control activities during the course of concrete batch. 3.0 DEFINITIONS QA/QC Manual QCP ITP Company Quality Assurance/Quality Control Manual Quality Control Procedure Inspection and Test Plan Proponent
4.0
SAFETY The safety Officer is responsible for the overall safety of the construction site. His responsibilities include site inductions ensuring work permits are valid, accident reports number of man hours worked and ensuring all works are carried out in the safest possible manor consistent with good construction practices.
5.0
REFERENCES SAES-Q-001 SAES-Q-005 09-SAMSS-088 09-SAMSS-097 Criteria for Design and Construction of Concrete structure. Concrete Foundation Aggregates for Concrete Ready Mixed Portland Cement Concrete
Approved Construction drawings

Concrete Batch Plant Page 2 of 4 MACO-QCCP-010

Technical Specification for Civil Works ITP Batch Plant Management MACO Safety Plan ASTM-C-33 ASM-C-94 6.0 Concrete Aggregates Ready Mixed Concrete
QUALITY CONTROL PROCEDURE 6.1 Vendor/Supplier shall be approved by Proponent prior to supply concrete to the project. Concrete mix Design shall be approved prior to the start of concrete production and in compliance with the technical specification and 09-SAMSS097. QA/QC Engineer shall verify compliance of aggregates, cement and water for Ready Mix Concrete per Saudi Aramco standards 09-SAMSS-088 and 09SAMSS-097. Calibration certificate of the batch plant shall be checked per Saudi Aramco specification 09-SAMSS-097 and controlled according to engineering procedure SAEP-1023. Project Engineer or Sit Engineer informs QA/QC Engineer for the concrete type, quantity and delivery time by internal concrete pouring request form for each production. Before mixing, the QC Inspector shall perform and verify the following items : 6.6.1 6.6.2 6.6.3 6.6.4 Check the Mix Design and Quality. Check the concrete type at the silo by the manufacturers certificate. Check approve admixture quality and quantity. Perform the moisture content test of the aggregates and make the correction of the mixing water. Make the concrete mixing water analysis for particles and TDS.
6.2
6.3
6.4
6.5
6.6
6.6.5
Page 3 of 4
MACO-QCCP-010

6.6.6
Check the cleanliness of the aggregates by verifying the washed water TDS in compliance with contract specification.
6.6.7 Check the formula and water/cement ratio of the contents entered into the computer of batch plant. 6.6.8 Verify/Check the periods whether the physical tests on concrete aggregates have been done by batching plant laboratory per Saudi Aramco specification 09-SAMSS-088. Verify the Batch Plant test equipment calibration status.
6.6.9
6.7 After mixing, the QC Inspector shall perform and verify the following items: 6.7.1 Check the computer print out after the concrete batching for the actual quantities and design values. Check fresh concrete temperature. Make the slump test at batch plant, whether it complies with the contract specification. Record the slump and temperature reading at the concrete dispatch ticket and sign it. Take a set of sample (Cylinder) for compressive strength test. Witness / Review the compression test. Authorize the concrete delivery Fill the internal concrete pouring request form ICPR No. HP-01 with attached related inspection report issued by batch plant. QC Inspector shall use quality record form QCCP-010-01-CBP as checklist as fill it as summary weekly performed inspections.
6.7.2 6.7.3
6.7.4
6.7.5 6.7.6 6.7.7 6.7.8
6.7.9
7.0
ATTACHMENTS
QCCP-010-01-CBP
Concrete Batching Plant Daily Monitoring.
Page 4 of 4
MACO-QCCP-010

DOCUMENT TITLE:
PROCEDURE FOR: MISCELLANEOUS METAL

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Miscellaneous Metal
Page 1 of 3
MACO-QCCP-011

MISCELLANEOUS METAL
1. SCOPE This quality procedure will apply for the inspection works for steel. 2. PURPOSE This quality procedure has been developed in order to describe the main procedure and performance related to quality control activities during steel works. 3. DEFINITIONS QMP QCP ITP : : : Quality Management Procedure Quality Control Procedure Inspection and Test Plan
4. REFERENCES: NAAMM ASTM-A269 ASTM-A53 SSPC SAES-H-101 Industrial-A123 12-SAMSS-007 Schedule Q
: : : : : : :
Architectural Metal Manufacturer. Stainless steel Tubing for General Services. Hot-Dipped and seamless steel pipe. Steel structure painting. Requirements for industrial coatings. Zinc Coating in Iron and steel Miscellaneous steel structure Quality Assurance and Control, Inspection & Testing.
5. QUALITY PROCEDURE The civil QC inspector shall verify all delivered materials in the job site to be in good condition and properly protected against damage to finished surfaces. Site measurement will be done to ensure that metal fabrication fit surrounding construction. Clean and strip primed steel items to bare metals where site welding is required. Verification of all opening sizes and dimensional tolerances are acceptable Verification of all supports is properly and correctly positioned. Installation in accordance with the shop drawings and manufacturers instructions.
Miscellaneous Metal Page 2 of 3 MACO-QCCP-011

Erection work to ensure square and level, horizontal or parallel to take of steps or ramp and free from distortion or defects detrimental to appearance or performance. Expansion joints will be provided as needed to allow for the expansion or contraction. Installation components plumb and level, accurately fitted, provide anchors, plate angles required for connecting railings to structure. Field weld anchors, touchup welds with primer and grind welds smooth. Conceal bolts and screw whenever possible. Mechanically cut galvanized finish surfaces. Do not flame cut. As installation is completed, wash thoroughly using clean water and soap, rinse with clean water. Do not use acid solution, steel wool or other abrasives. Remove burrs, weld spatter, weld slag, arc strikes, sharp edges, rust, scale, grease and foreign matters prior to finishing. For aluminum items re-anodizing can only be done by removing the part and returning it to the anodizer. 6. ATTACHMENT 6.1 QCCP-011-01-MM : Miscellaneous Metal
Miscellaneous Metal
Page 3 of 3
MACO-QCCP-011

DOCUMENT TITLE:
PROCEDURE FOR: SITE NON-ELECTRICAL UTILITIES

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Site Non-Electrical Utilities
Page 1 of 9
MACO-QCCP-012

SITE NON-ELECTRICAL UTILITIES

1 Scope
This quality procedure applies to the installation of Fire/Raw Water, Drinking Water, Sanitary Sewer, piping, fittings, accessories, bedding and connections. 2 Purpose
The purpose of this quality procedure is to provide a procedure for the installation of all site Non-Electrical Utilities. 3 References
Construction Specifications & IFC Drawings.
Definitions None
5 5.1
Responsibilities The discipline supervisors and/or foremen are responsible for the installation activities assuring all works being implemented are in conformance with specifications and approved drawings.
5.2 The discipline QC Inspectors shall ensure that approved quality control procedure is implemented throughout the course of the installation. Inspection shall be done on materials or work, which will be incorporated to the system. They shall coordinate with Proponent Representative regarding inspection and testing activities. Documentation of all inspection and tests made shall also be their responsibility. 6 6.1 Procedure General Requirements 6.1.1 Thermoplastic and RTR pipes, fittings and accessories shall be stored and handled in accordance with manufacturers recommendation and the requirements of Standard Operating Procedure.
Page 2 of 9
MACO-QCCP-012

6.1.2 Concrete requirements shall be in accordance with work procedure MACO-QCCP-005, Concrete Works. 6.1.3 Excavation, Trenching, Backfilling and Compacting shall be carried out in accordance with work procedure MACO-QCCP-003, Excavation, Trenching, Backfilling and Compacting, and as herein specified. 6.1.3.1 All excavations shall be restored so its surface contour blends in with the surrounding area. All existing pavements (asphalt and concrete) disturbed during trenching operation shall be restored to their original condition or better. 6.1.3.2 No construction shall start until the design of the dewatering system (if required) has been approved by the Proponent Representative. Dewatering shall be carried out in accordance to Method Statement submitted by Dewatering SubContractor and approved by Proponent Representative. 6.1.3.3 The bottom of the trench shall be dry before pipe is installed. 6.1.3.4 At the end of every work shift, personnel performing the pipe installation shall ensure that the pipe ends are capped to prevent the egress of foreign material and the piping are anchored to prevent floatation. 6.1.3.5 The depth of the trench shall be dug deep enough to provide a minimum ground cover above the top of the pipe, as required in Table 2 of SAES-S-070, and a ground bed of at least 150 mm in depth below the bottom of the pipe. 6.1.3.6 The width of the trench should be wide enough to allow room for jointing, but in any case not less than shown in Table 1 of SAES-S-070. 6.1.3.7 The ground bed shall provide uniform and adequate support and drainage along the entire length of the piping. In subkha areas, a base support layer of crushed stone base material 150 mm deep 38 mm maximum size shall be provided. The crushed stone base material shall be compacted to at least 95% of ASTM D698.
Page 3 of 9
MACO-QCCP-012

6.1.3.8 A bedding layer of clean sand, 150 mm in depth is required for all trenches. The sand shall be free of debris and rocks and compacted to at least 70% relative density, or 95% proctor density as per ASTM D698, whichever gives the greater density. 6.1.3.9 The trench bottom shall be continuous, smooth, free of rocks, and to the line and grade shown on the installation drawings. The pipe shall have essentially continuous support and not rest on the joint. For RTR piping, the trench contour shall not cause the joint angular deflection or the pipe-bending radius to exceed the manufacturers limit. 6.1.3.10 The minimum trench width from the bottom to 300 mm above the top of the pipe shall be as shown in Table 1 of SAES-S070. 6.1.3.11 Trenches maybe excavated wider than the trench width above the LNTL (Line of Narrow Trench Limit), if necessary. 6.1.3.12 Sheeting or shoring shall be in accordance with the Proponent Construction Safety Manual, Section II. All underpinnings, bracings, and shoring shall be provided as necessary to protect and preserved all existing buildings, fences, walls, utilities, and other structures. 6.1.3.13 The minimum cover over the top of the pipe shall be as shown in Table 2 of SAES-S-070 unless noted otherwise. 6.1.3.14 Piping shall have steel sleeves at government road crossings and railroad crossings in accordance with Saudi Aramco Standard Drawing AC-036660 or AB-036880. 6.1.3.15 If it is impossible to achieve the minimum cover as specified in this Standard, the piping shall be protected by a reinforced concrete slab, or metallic casing in accordance with SAES-L-046. 6.1.3.16 The trench bottom shall be continuous, smooth, free of rocks, and to the line and grade shown in the installation drawings. The pipe shall have essentially continuous support and not rest on the joint. For RTR piping, the trench contour shall not cause the joint angular deflection or the pipe-bending radius to exceed the manufacturers limit.
Page 4 of 9
MACO-QCCP-012

6.2
Assembly and Installation 6.2.1 All pipes shall be installed in accordance with IFC Drawings, Construction Specification and applicable provisions of SAES-S010, SAES-S-040, SAES-S-060, and SAES-S-070 as herein specified. 6.2.1.1 Pipes and fittings shall be inspected before installation to detect defects. Defective materials shall be marked with paint and promptly removed from the site. 6.2.1.2 When placing pipe in the trench, fabric slings shall be used. The pipe shall not be dragged along the bottom of the trench, nor humped, and it shall be supported by the sling while being fitted to the adjacent pipe. No metal tools or heavy objects should be permitted to come into unnecessary contact with the pipe or fittings. 6.2.1.3 The pipe shall be laid at the level and gradient stipulated, on a prepared bed 150 mm deep with special hollows made for the joints. The pipe shall be aligned carefully in both the horizontal and vertical planes. Pipe shall be uniformly bedded throughout its length. 6.2.1.4 Every precaution shall be taken to prevent foreign matter from entering the pipe or fittings. During laying operations, no debris, tools, cloth or other materials are to be allowed to enter the pipe. 6.2.1.5 Deflection at joints shall not exceed the maximum recommended by the manufacturer. 6.2.1.6 As the work progresses, interior of the pipe shall be cleared of dirt and other foreign material. 6.2.1.7 The bottom of the trench shall be dry before pipe is installed. 6.2.1.8 At the end of every work shift, pipe ends shall be sealed by temporary watertight plugs to prevent the egress of foreign material. 6.2.1.9 The minimum clear distance between raw and drinking water lines, if installed in the same trench, shall be 300 mm.
Page 5 of 9
MACO-QCCP-012

6.2.1.10 All water supply piping shall have a minimum cover of 24 in. (610 mm) for all pipes 3 in. (90 mm OD) diameter and larger; and 12 in. minimum cover (305 mm) for smaller than 3 in. (90 mm OD) pipes. 6.2.1.11 Underground parallel water supply and fire water piping shall have a minimum horizontal clear distance of 12 in. (305 mm). 6.2.1.12 A branch piping of a raw/firewater combined distribution system, serving firewater systems of a building or a facility shall be connected upstream of the isolation valve of the raw water supply piping.
6.2.2 RTR Piping 6.2.2.1 The installation of RTR piping shall be done by personnel trained in the proper handling and usage of applicable materials and equipment. 6.2.2.2 Adhesive-bonded RTRP Joints shall be assembled in accordance with the manufacturers procedures. Heating blankets shall be used to cure adhesive bonded RTRP joints. 6.2.2.3 RTR piping of 250 mm nominal pipe size and less may be assembled next to, or in the trench. Piping larger than 250 mm nominal pipe size shall be assembled in the trench. 6.2.2.4 For trenches 2 M deep or less, pipe assembled next to the trench shall not be moved within three pipe lengths of an uncured joint. The pipeline shall be lowered into the trench progressively to avoid excessive joint angular deflection. 6.2.2.5 For trenches deeper than 2M, pipe shall be assembled in the trench. 6.2.2.6 Pipe and fittings shall not be dropped into trench. Protect from all types of impact and excessive overheating causing deformation or permanent damage to pipe.
Page 6 of 9
MACO-QCCP-012

6.2.2.7 Bedding in the pipe zone should be clean sand. Sand bedding under the pipe should be a minimum of 150 mm in thickness. 6.2.2.8 Sand shall be uniformly compacted around the pipe with particular care given to the bedding beneath the haunches of the pipe. Sand may be compacted by hydraulic methods if the native soil in which the trench is excavated is free draining. If trench is not free draining, placement of damp sand will facilitate compaction. Sand bedding and backfill should extend a minimum of 300 mm above the pipe. 6.2.2.9 Backfill shall be deposited in 150 mm maximum layers to a point at least 600 mm above the top of the pipe, each layer being compacted as required. 6.2.2.10 In-place tests of soil density shall be made in accordance with ASTM D1556 or ASTM D2167. 6.2.2.11 Mechanical compactors may be used provided harmful shock loads are not transmitted to the pipe. Maintaining a space of at least one foot between tamping feet and pipe wall should avoid damage to the pipe wall. 6.2.2.12 The minimum earth cover above the pipe crown shall be 900 mm (3ft). 6.2.3 Thermoplastic Piping 6.2.3.1 Before any pipe or fitting is lowered into the trench it shall be carefully checked to ensure that it is not cracked or damaged in any way. Damaged pipe shall either be cut, so that flawless pipe is obtained with the least possible waste. 6.2.3.2 Joints shall be made in accordance with ASTM D2855. Solvent cement shall conform to ASTM D2564. 6.2.3.3 After the pipe has been made, the piping shall not be moved until the drying time listed in Table 3 of SAES-S-070 has elapsed. To limit movement of a pipe string, the first pipe shall be backfilled with the joint exposed.
Page 7 of 9
MACO-QCCP-012

6.2.3.4 Pipe shall not be exposed to direct sunlight and provisions shall be made for shading any pipe which is left in the open or uncovered in trenches. 6.2.3.5 Sewer pipe shall be laid beginning at the low point of the system, true to the grades and alignment indicated with unbroken continuity of invert. Pipes shall be placed with bell ends facing upstream. 6.2.4 Water, Sewer Location and Crossing 6.2.4.1 No sewer main shall be located closer in a horizontal direction, than 3M to a water main. 6.2.4.2 Where a sewer main or lateral cross below a water main or water service line, the sewer line shall in all cases be installed at least 30cm below the water line. 6.2.4.3 Where the water main, or service line crossing above the sewer line or lateral has less than 30cm vertical distance, the sewer pipe shall be fully encased with 150mm thick of concrete all around for a distance of 3M each side of the crossing (measured perpendicular from the water main or service line). 6.2.4.4 The sewer main or laterals may cross above a water main or water service line with the approval of Proponent Representative. In such a case, the sewer pipe shall be fully encased with concrete. 6.2.4.5 Where a water or sewer line crosses electrical or telephone cables, approval from the concerned authorities shall be obtained. 6.2.4.6 The minimum crossing or parallel clearance between direct buried cables or conduits and underground piping, including hydrocarbon pipelines that fall outside of the scope of SAES-B064, shall be 30cm (12 in.). 6.2.4.7 Sewer lines passing through roads and pavements having cover less than 900mm shall be sleeved or concrete encased. 6.2.4.8 Parallel building sewers and water service lines, if necessary, may be laid in a common trench provided that all of the following requirements are met:
Page 8 of 9
MACO-QCCP-012

6.2.4.8.1 The bottom of the water pipe(s), at all points, shall be at least 12 in. (305mm) above the top of the sewer line. 6.2.4.8.2 The side(s) of the water pipe(s), at all points, shall be at least 12 in. (305mm) clear horizontally from the side of the sewer line. 6.2.4.8.3 The water pipe(s) shall be placed on a solid shelf of the common trench, or the water line shelf be of select backfill compacted to a minimum of 95% density as per ASTM D698. 6.2.4.9 Proponent Representative shall be notified before any connection is made to the existing system. Elevation of existing pipes shall be field verified at tie-in points prior to construction. 6.2.4.10 Adapter coupling/flange shall be provided at tie-in points as required. 6.3 Pressure Testing 6.3.1 Pressure Testing, inspection and repair in case of any leakages during hydrotest shall be carried out in accordance with Work Procedure MACO-QCCP-010, Pressure Testing. 6.3.2 Underground piping shall be partially backfilled with all joints exposed during the hydrotest. The exposed joints shall be shaded from direct sunlight, and the hydrotest shall be performed so that the temperature of the thermoplastic piping material or the temperature of the test water does not exceed 400C during the test period. 7 Documentation 7.1 None
Page 9 of 9
MACO-QCCP-012

DOCUMENT TITLE:
PROCEDURE FOR: STRUCTURAL STEEL

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Structural Steel
Page 1 of 4
MACO-QCCP-013

STRUCTURAL STEEL
1. SCOPE This quality procedure will apply for the fabrication and erection of STRUCTURAL STEEL in compliance with the contract drawings and specification. 2. PURPOSE This quality procedure has been developed in order to describe the main procedure and performance related to quality control activities during fabrication and erection works. 3. DEFINITIONS QMP QCP ITP : : : Quality Management Procedure Quality Control Procedure Inspection and Test Plan
4. REFERENCES: SAES-M-001 : Basic Criteria for miscellaneous steel structure. SAES-M-100 : Saudi Aramco building code. SAES-H-001 : Selection requirements for industrial coatings 12 SAMSS-008 : Miscellaneous steel structure. Schedule Q Quality Assurance and Control, Inspection & Testing. SSEM safety plan Approved construction drawings. 5. QUALITY PROCEDURE All structural steel shall be sand blasted and primed with a zinc phosphate or zinc chromate primer in the shop as per project specification. Where steel is to receive subsequent top costs the primer shall be from the same manufacturer as to top coats. Do not paint surfaces, which are to be welded. Apply one full coat of paint to surfaces, which are inaccessible after assembly or erection.
Structural Steel
Page 2 of 4
MACO-QCCP-013

Touch up all primer where damaged during erection. Fabricate in accordance with SAES-M-100 or as indicated on approved shop drawing. Shearing, flame cutting and chipping shall be dimensionally true to achieve indicated lengths and fitting requirement. Develop required camber for members. Welded connections shall comply with AWS D1.1 procedures, appearance, testing and quality of welds and for method used in correcting welded work. All welds shall be pre-qualified or shall be tested and qualified in accordance with AWS D1.1 Connections shall be as shown on the contract drawings. Drill or punch holes at right angles to surface metal, do not enlarge by burning. Punched holes shall be clean cut without torn or ragged edges. ASTM A325 bolted connections shall conform to the requirements of the specification for structural joints using ASTM A325 or A490 bolts. Friction type bolts shall be installed with load indicator washers in accordance with the manufacturer recommendations. Plate washers and additional lock nut shall be used in all slotted connections. Deliver, unload and handle all structural steel in such a manner as not to distort or damage. Replace damaged or distorted materials with approved materials without additional cost to Saudi Aramco. Place column setting plates and beam bearing plates at required elevations and pack grout under plates to provide a bearing plate surface, which is fully supported, flat and level at the correct elevation. Make allowance for thermal expansion of length of members when installing members. Use bolts for field fastening of steel to concrete, masonry and steel to steel connections. Use field welding only when indicated on drawings. Notify Proponent representative for inspection. Provide all bracing, temporary bracing and accessories required for complete erection.
Structural Steel
Page 3 of 4
MACO-QCCP-013

Drifting to enlarge holes is prohibited. Burning of hole prohibited. Installation and tightening of A325 bolts will comply with section 7 of RCSC specification. Gas cutting is prohibited on major members. Cutting, fitting, drilling and tapping of materials as required for proper and complete installation work. After erection cleaning will be done. Touch up with same paint for the exposed steel will be done. 6. ATTACHMENT 6.1 QCCP-013-01-SS : Structural Steel
Structural Steel
Page 4 of 4
MACO-QCCP-013

DOCUMENT TITLE:
PROCEDURE FOR: JOINT SEALANTS

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Joint Sealants
Page 1 of 3
MACO-QCCP-014

JOINT SEALANTS
1. SCOPE This quality procedure will apply for the inspection works for. 2. PURPOSE This quality procedure has been developed in order to describe the main procedure and performance related to quality control activities during steel works. 3. DEFINITIONS QMP QCP ITP : : : Quality Management Procedure Quality Control Procedure Inspection and Test Plan
4. REFERENCES: NAAMM ASTM-A269 ASTM-A53 SSPC SAES-H-101 Industrial-A123 12-SAMSS-007 Schedule Q
: : : : : : :
Architectural Metal Manufacturer. Stainless steel Tubing for General Services. Hot-Dipped and seamless steel pipe. Steel structure painting. Requirements for industrial coatings. Zinc Coating in Iron and steel Miscellaneous steel structure Quality Assurance and Control, Inspection & Testing.
5. QUALITY PROCEDURE The civil QC inspector shall verify all delivered materials in the job site to be in good condition and properly protected against damage to finished surfaces. Site measurement will be done to ensure that metal fabrication fit surrounding construction. Clean and strip primed steel items to bare metals where site welding is required. Verification of all opening sizes and dimensional tolerances are acceptable Verification of all supports is properly and correctly positioned. Installation in accordance with the shop drawings and manufacturers instructions.
Joint Sealants
Page 2 of 3
MACO-QCCP-014

Erection work to ensure square and level, horizontal or parallel to take of steps or ramp and free from distortion or defects detrimental to appearance or performance. Expansion joints will be provided as needed to allow for the expansion or contraction. Installation components plumb and level, accurately fitted, provide anchors, plate angles required for connecting railings to structure. Field weld anchors, touchup welds with primer and grind welds smooth. Conceal bolts and screw whenever possible. Mechanically cut galvanized finish surfaces. Do not flame cut. As installation is completed, wash thoroughly using clean water and soap, rinse with clean water. Do not use acid solution, steel wool or other abrasives. Remove burrs, weld spatter, weld slag, arc strikes, sharp edges, rust, scale, grease and foreign matters prior to finishing. For aluminum items re-anodizing can only be done by removing the part and returning it to the anodizer. 6. ATTACHMENT 6.1 QCCP-014-01-JS : Joint Sealants
Joint Sealants
Page 3 of 3
MACO-QCCP-014

DOCUMENT TITLE:
PROCEDURE FOR: PRESSURE TESTING

Index 1 2 3 4 5 6 7 Scope Purpose References Materials Procedure Lay-Up Procedure Documentation Page 2 2 2 2 2 5 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Pressure Testing
Page 1 of 8
MACO-QCCP-015

PRESSURE TESTING
1 Scope: 1.1 This procedure covers pressure testing of pipelines: 2 Purpose: 2.1 This procedure is intended to define preparation and method used to conduct Pressure Testing of pipes as required in the specifications. 3 References and Standards:
Royal Commission Standards: 15053 Testing Of Piping
Safety: 4.1 All necessary work permits shall be obtained prior to hydro testing. Hydro test shall be performed in accordance with the client approved procedure only.
4.2
5 5.1
Procedure: All materials within the piping system shall be checked to ensure compliance with the design limit and to verify that the pressure rating meet or exceed the specified test pressure. The pre-pressure test packages shall be issued to client for review at an agreed time before the test starts.
5.2 Pipe Joint and Fittings: 5.2.1 Underground process piping shall be tested prior to backfilling. The test pressure shall be maintained for a minimum of 2 hours while the joints are inspected for leakage. If for justifiable safety reasons the line must be backfilled, then the joints shall remain exposed during testing, otherwise the test shall be a 24 hour recorded test. The test pressure shall be in accordance with client specifications.
Pressure Testing Page 2 of 8 MACO-QCCP-015

5.2.2 Vents shall be provided at all high points in the system. Drains shall likewise be provided at all low points in the system. 5.2.3 Piping System being strength tested shall be protected from over pressure by relief valve of adequate capacity to relieve at 5% above the strength pressure. 5.3 Test Equipment: 5.3.1 Equipment to be used on the test shall be checked to ensure that respective pressure ratings are consistent with the test requirements. Necessary isolation valve rated for manifold pressure between the test manifold and the system being tested. 5.3.2 Test pump shall be placed on the firm ground and connected at the pipe having the lowest point or elevations where possible. 5.3.3 A bleed valve shall be provided to protect the piping and equipment from over pressurization in addition to pressure relief valve. The bleed valve shall be readily accessible in case immediate depressurization is required. 5.3.4 Pressure gauges shall be calibrated as per client specifications. All pressure gauges shall have a range such as the pressure is within 30 to 80 percent of the full range. 5.3.5 Gauges calibration interval shall not exceed one (1) month or client specification. 5.3.6 Calibration certificates shall be made available prior to pressure testing. 5.3.7 Relief valves shall be tested, dated and tagged within one (1) week prior to hydrotest and sizing of the relief valves shall be in accordance with the client specifications. 5.3.8 Pressure monitoring gauge shall be installed at the pipe and not at the pressure pump. Minimum of two (2) pressure gauges whose accuracy shall be 5% of one another shall be located at the pump manifold and the others on the system. 5.3.9 Test medium to be used shall be in accordance with the client specifications. Chloride content of water shall be less than 50 mg/L when testing stainless steel.
Pressure Testing
Page 3 of 8
MACO-QCCP-015

5.4 Sectionalizing System may be separated in to sub-system for testing. A diagram shall show the limit and method of isolation for systems or sub-systems shall be prior to testing. Test pressure shall be as specified in the project line list. 5.5 Pressure Testing: 5.5.1 Lines which have not been backfilled or are above the ground shall be tested for a sufficient time, which shall not be less than 30 min. to determine that there are no leaks. 5.5.2 Fill the system / sub-system with approved test fluid which shall be introduced at the lowest point of the system. All vents shall be opened during filling and closed when entrained air is removed, then build the pressure slowly. 5.5.3 At 50% of the strength test pressure, pressurization shall be stopped to check for leaks. 5.5.4 If any leakage is found, the system shall be de-pressurized and then de-watered. After repair, the system shall be re-filled and pressurization shall be re-initiated. 5.5.5 After satisfactory preliminary checks for leaks at 50% of strength test pressure, the pressure shall be increased in steps no greater than onetenth of the strength test pressure with at least 10 minutes hold at each step to permit inspection for leakage. 5.5.6 If no leaks are discovered during these steps, pressurization shall be continued up to the required test pressure. The lines shall be considered satisfactory if there is no evidence of leakage or pressure losses after the specified test period. 5.5.7 Upon completion, the system shall be bled and the line s shall be drained. Vents are to be fully opened. 5.5.8 All test manifolds shall be pre-tested separately from the system to at least 1.2 times the system test pressure but not less than the pump discharge pressure. 5.5.9 System Valve Testing shall be in accordance with client specification and approved valve testing procedure.
Pressure Testing
Page 4 of 8
MACO-QCCP-015

6 6.1
Lay-up Procedure: Upon completion of final pressure test, the hydro test water shall be drained completely. Compressed air shall be blown until such time the system is thoroughly dried out. Open air inlet and exit point to dry the system.
6.2
6.3
7 7.1
DOCUMENTATION Pre-Test Punch List QCCP-015-01-PT QCCP-015-02-PT QCCP-015-03-PT
7.2 Pressure Test Certificate 7.3 Valve Test Certificate
Pressure Testing
Page 5 of 8
MACO-QCCP-015

PUNCH LIST
QCCP-015-01-PT
PUNCHLIST No. TEST PACK No.
Item No. Drawing No. Category Action By: Description
AREA: SYSTEM:
Originator Sign. Date Comp. Sign Date
Category A: To be corrected before pressure test. Category B: To be corrected before or after pressure test.
MACO SUPERVISOR
Pressure Testing
Page 6 of 8
MACO-QCCP-015

PRESSURE TEST CERTIFICATE
QCCP-015-02-PT
TEST PACKAGE: SYSTEM & SERVICE: REFERENCE STANDARDS: TEST TYPE: PLANT NO.:
S. No.
Drawing No.
Spool No.
S. No.
Drawing No.
Spool No.
TEST PRESSURE: TEST MEDIUM: EQUIPMENT: GAUGE No. 01: GAUGE No. 02: RELIEF VALVE No.:
LAY-UP REQUIRED: TEST DURATION:
Calibration Date: Calibration Date: Calibration Date:
Expiry Date: Expiry Date: Expiry Date:
REMARKS:
MACO SUPERVISOR
Pressure Testing
Page 7 of 8
MACO-QCCP-015

VALVE TESTING RECORD
QCCP-015-03-PT
MANUFACTURER PRESSURE SEAT TYPE MANUFACTURER PRESSURE SEAT TYPE MANUFACTURER PRESSURE SEAT TYPE Royal Commission for Jubail & Yanbu P.O. No. : : : : : : : : : TEST No. TEST MEDIUM : :
TEST No. TEST MEDIUM
: :
TEST No. TEST MEDIUM PRESSURE
: :
Item No.
Valve Identification
Dia.
Rating
BODY (PSI)
SEAT(A) (PSI)
SEAT(B) (PSI)
BACK SEAT (PSI)
ACC
REJ
REMARKS:
MACO QA/QC INSPECTOR
Pressure Testing
Page 8 of 8
MACO-QCCP-015

DOCUMENT TITLE:
PROCEDURE FOR: THRUST BORING

Index 1 2 3 4 5 6 Purpose Scope References Definitions Procedure Risk Assessment Page 2 2 2 2 2 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Thrust Boring
Page 1 of 13
MACO-QCCP-016

THRUSTBORING PROCEDURE
1 Scope This method statement is only applicable to the above works associated with the construction of the new water main pipeline. 2 Purpose The method statement defines the procedures to be adopted and the controls to be exercised in the placing of the 1200mm dia. steel liner and all associate works. 3 References 3.1 Aject Health and Safety Policy 3.2 Site Health Safety Plan 4 Definitions PPE Personal Protective Equipment HAVS Hand Arm Vibration Syndrome COSHH Control of Substances Harmful to Health 5 Procedure 5.1 Prior to commencing any work all personnel will have attended the appropriate Site Induction Training. 5.2 All necessary Permits to Work will have been obtained by the main contractor and be displayed on site as required. 5.3 Prior to any works commencing, the main contractor shall set out works in accordance with the latest revised information. Line and control points will be clearly marked as appropriate for use by AJECT. 5.4 Plant and equipment associated with the works will be delivered to the site and off loaded in the required pre-determined position suitable for the works.
Thrust Boring
Page 2 of 13
MACO-QCCP-016

5.5 Following completion of the drive pit, shuttering and concreting works will be required to be carried out for the construction of the thrust wall and front sealing eye wall.
5.6 Once the shutters are fabricated, mesh reinforcement placed the required concrete will be called off and delivered and placed using either a proprietary concrete pump if available or a simple concrete skip in conjunction with suitable craneage. 5.7 Following completion of the above works and a suitable curing time period the shutters will be stripped and removed from within the cofferdam. 5.8 The guide slide rails / jacking equipment will be then positioned to the correct alignment and level to suit the steel sleeve pipe. Once set concrete haunching will be placed to maintain the position. 5.9 A rubber sealing eye complete with steel plate ring will be attached to the concrete front sealing eye wall. This ring allows entry of the tunneling machine while preventing ground loss and bentonite slurry loss. 5.10 The tunnel machine, TBM to be utilized will be an Iseki type machine. The TBM is equipped with a soft ground cutting head. The head itself is equipped with carbide tipped tools to cut the entire face of the tunnel. The machine is a no man entry and consists of a sealed face bulkhead. 5.11 On completion of the above works, the TBM is lowered into the drive pit onto the guide rails. 5.12 The machine is then jacked forward entering the concrete sealing eye through the rubber sealing ring. At this point the face of the machine is charged with water / slurry to provide the necessary face support. 5.13 The sheet piles over the extent of the tunnel entry are then extracted to a level just above the crown of the tunnel, to allow entry of the TBM into the ground. 5.14 The machine then commences excavation. The excavated material passes through the openings in the cutting wheel into the crushing / mixing chamber. Within the chamber, the rear of the head acts as a conical crusher, reducing the excavated material to a size suitable for conveying to the surface settlement tank by use of slurry pumps. Water is injected into the crushing
Thrust Boring
Page 3 of 13
MACO-QCCP-016

chamber via nozzles to assist with ground support and to clear the excavated material. 5.15 The excavated material conveyance is controlled by pressurized feed and return pumps. The pumps have variable speed controls to adapt to varying ground conditions and to balance the flow rates and control settlement above the tunnel line. 5.16 Additionally the machine is fitted with a by-pass valve system which allows for the washing out of the feed and discharge lines. The system also isolates the cutting head, thus support can be maintained to the face while the slurry system is disconnected during the process to place the jacking pipes. 5.17 As stated, the excavated material is conveyed to a settlement tank on the surface. The feed water is drawn from this tank. The excavated material settles within the tank and is required to be removed by an excavator at various intervals during the tunneling process. The water level within the tank will also require topping up at intervals during the process. 5.18 Control of the tunneling process is via a containerized surface mounted control cabin / power pack. A CCTV camera in the rear of the machine details all relevant data the operator requires. 5.19 A laser guidance system is utilized. The laser is set within the drive shaft and the beam shines along the tunnel length to a target within the rear of the TBM. This information is also displayed to the operator, who can control the TBM steering rams to guide the machine to the specified tolerances. 5.20 The TBM will be advanced by utilizing the pit bottom jacking system, retracting the rams as the full stroke is reached and placing steel spacer units and continuing the process until there is sufficient space for the first casing pipe to be lowered. 5.21 At this stage the rams will be extracted and the spacer blocks removed and the slurry and power cables to the TBM will be disconnected. 5.22 The steel casing pipe (6m long) will be lowered and the pipe welded to the back of the TBM can. Once welding is completed the TBM services will be re-established and the jacking process recommenced. 5.23 This process continues until the first casing pipe is fully pushed and the process repeated lowering the second pipe. The joints between the pipes are
Thrust Boring
Page 4 of 13
MACO-QCCP-016

fully butt welded. On completion of the welding, the process as described above is repeated until the drive is completed. 5.24 Prior to the tunnel works being completed the reception pit will have been prepared for receiving the TBM. A suitable level base will have been constructed. This may be either stone or concrete depending on the conditions encountered. 5.25 A similar sealing eye will have been constructed previously within the reception pit. A block work wall will have been constructed within the sealing eye void, the void space between the blocks and the profile of the sheet piles will be filled with bentonite slurry. 5.26 The block work wall will be supported with timbers and steel work to prevent the wall from being pushed out by the TBM. 5.27 As the TBM reaches the position of the reception pit entry, the required sheet piles will be extracted to just above the tunnel crown level to allow passage of the machine. 5.28 The machine then cuts through the block work wall and enters the reception pit onto a set of either steel rails or heavy duty timbers placed to the underside of the TBM to prevent it from dropping and to allow for smooth pushing into the pit. 5.29 The TBM is then pushed through the entry eye to a position within the pit where it can be removed. 5.30 The rubber sealing ring within the reception pit can be removed, placing a cement grout to the annulus between the concrete eye and the casing pipe as necessary. 5.31 Within the drive pit the casing pipe will be cut to the correct position to allow for the threading of the actual product pipe. 5.32 The rubber sealing eye ring will also be removed as described in 5.29.
5.33 The slurry tanks will be emptied of water and excavated material. Main contractors responsibility. 5.34 All plant and equipment will be stripped and cleaned and prepared for removal from site.
Thrust Boring
Page 5 of 13
MACO-QCCP-016

5.35 An auger pushing rig will then be established within the drive pit to suit the level of the product pipe. 5.36 The product pipes will be prepared for pushing by having simpler timber skids attached to the outside to maintain the desired position of the pipe, once inserted into the casing pipe. The skid / spacer timbers will be secured to the product pipe using steel band it wire. The timbers will be notched to prevent the skids from being dislodged during the pushing process. 5.37 The first 6m long pipe will be lowered and pushed into the tunnel to the desired position to allow welding of the following pipe. 5.38 The second pipe will be lowered and jointing works carried out by the main contractor. Once the necessary testing and coating works have been carried out the second pipe will be pushed to the correct position for the process to be repeated. 5.39 On completion of the pushing process to the required positions the auger pushing rig will be stripped down and removed from the jacking pit. 5.40 Timber shutters will be constructed to both ends of the tunnel over and around the inserted product pipe. 5.41 Two pipes will be installed within the top of the shutters to allow for grouting operations and for the expelled air to exit the void space. 5.42 Grouting and the annulus between the casing pipe and the product pipe will be undertaken using the specified grout mix. The grout will be placed utilizing a grout mixing pan and pump. The grout will be placed from the upper end of the tunnel and will flow through the void space. 5.43 Successful grouting of the void space will be demonstrated when the grout flows from the upper breather pipes on the down stream end. A header pipe will also be utilized on the upstream end to allow simple gravity to fill the remaining void space. 5.44 Once this operation has been completed and the shutters removed the works shall be handed back to the main contractor for connections and completion works to be carried out. The pits will then be subsequently backfilled.
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Page 6 of 13
MACO-QCCP-016

EMERGENCY ARRANGEMENTS: 5.45 Members of the team shall be trained in first aid; the first aid kit is available at the work area and will be kept with the workforce. Additional support will be provided by the main contractor. EMERGENCY PURPOSES: 5.46 All personnel shall be inducted into the main contractors Emergency and Fire Safety Plan. A tool box talk will be given on the procedures and the procedures will be displayed on site. ENVIRONMENTAL ISSUES: 5.47 Environmental spill kits will be available for use at the works location.
5.48 AJECT will be informed of all necessary procedures by Manar Arabian Corp. and will be provided any equipment necessary to allow conformity. OTHER WORKS: 5.49 All instructions given by the banksman must be followed and works cease as appropriate. 5.50 AJECT will be notified of any particular other safety issues within site inductions. Any equipment to conform to any particular site rules which are not specifically contained within this method statement will be provided by the main contractor. 5.51 AJECT will be informed of any other works being carried out within the general working area which may affect our operations. 5.52 The main contractor is responsible for obtaining any permits required during the sub-contract works including all access and hot works permits that may be required and the provision of any equipment required by the issuing of the said permits; for example fire fighting equipment.
Risk Assessment 6.1 Before any work process is undertaken the manager shall ensure a risk assessment is undertaken for all operations likely to expose persons to any
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Page 7 of 13
MACO-QCCP-016

hazard. Where the hazard cannot be eliminated, risk control measures shall be identified and the residual risks rating identified. 6.2 A competent person who possesses the necessary training, experience and expertise has undertaken the risk assessment. It shall be briefed out to all those involved in the operation and any pertinent feedback incorporated. 6.3 The risk assessment will be reassessed whenever a significant change in the process, where new equipment or materials are introduced, or when any person has any knowledge of the assessment being invalid.
Key L The likelihood of an incident occurring

1 Very Low 2 Low 3 Possible 5 Very Likely
The level of severity if the incident occurs in terms of injury, illness or damage.
1 Minor Injury, damage or sickness 2 First aid injury or Lost time illness 3 Reportable injury or illness, substantial damage 4 Major injury, amputation or long term absence 5 Fatal Injury or catastrophic damage
Risk Rating: R = L x S
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Page 8 of 13
MACO-QCCP-016
QA/QC PLAN
ALTERNATE SANITARY WASTEWATER COLLECTION PIPELINE FROM PS#B2 TO PS#1 DOCUMENT No. MACO-QCCP-016 REV. 0
REF.
Hazard
PERSONS AFFECTED
Initial Risk L S R
Avoidance/Control Measures L
Resultant Risk S R
Cranes / Rigging / Slinging
Banksmen
1 9 Appointed Crane coordinator, Trained Slingers & Signallers. Certified Lifting tackle, visual inspection. Certified Crane 12 monthly thorough inspections, weekly recorded, daily visual. (6 monthly if used for manriding). Personal positioning no standing under loads. 8 Assessments to be undertaken. Mechanical lifts to be used wherever practical. Gloves to be worn. Good posture to be maintained whilst lifting. 10 Suitable footwear to be worn. Practice good housekeeping. Weekly inspections of the Workplace by competent person. 15 Excavations or edges of falls to be guarded. Daily inspection by competent person. Weekly record of inspection. 15 Fire Plan to be established. Trained fire extinguisher users. Regular inspection of equipment. Regular drills. 2
Manual Handling
All on site
Slips, Trips and Falls
All on site Visitors
Excavation falls
All on site
Fire
All on site Personnel Visitors
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Page 9 of 14
MACO-QCCP-016
QA/QC PLAN
REF.
Hazard
PERSONS AFFECTED
Initial Risk L S R
Resultant Risk S R
Ladders / Scaffold / Falls from Height
General Labourers
Crushing by plant and equipment
All site personnel Visitors
Disease
General Labourers
Environmental Concern (Contamination of Controlled Waters)
Environment
10
Dermatitis, skin burns Health Impact
All on site
11
Noise
All
12 Correct use of ladders footed or tied. Correct angle of rake. Correct erection and use of scaffold / trained personnel. 12 Trained operators. High visibility clothing. Planned traffic routes. Banksmen for unsighted operations and reversing wagons. 15 Practice good hygiene. Provide good welfare. Induction and awareness of Weils Disease. 6 All diesel plant and tanks to be bonded. Fuel stored to be locked against vandalism. Drip trays to be used. Settlement tanks to be used. Spill kits to be provided. 4 COSHH Assessments to be made and briefed out Ensure safe / secure storage and disposal of materials. Ensure fire and first aid facilities are available. Wear PPE as dictated by COSHH assessment. Provide hand Protection. Provide adequate welfare facilities, cleansing materials and barrier creams. 4 Ear protection to be worn when working with or near noisy equipment or as determined by noise assessments. Select silenced equipment where possible.
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MACO-QCCP-016
QA/QC PLAN
12
Small Tools
Operators
13
Flying Debris / Dust
All
14
HAVS
Operators
Equipment to be regularly inspected and maintained. Post warning signs and established hearing protect zones. 9 Only use experienced operators. Equipment to be regularly inspected and maintained. Correct PPE to be worn. 6 Minimize operations that produce flying debris. Provide respiratory / eye protection. Cordon off areas as appropriate. 9 Use anti-vibration tools where possible. Use anti-vibration PPE. Obtain Particle velocity reading for equipment and calculate maximum working times per 8 hour shift. Rotate Operators using equipment. Equipment to be regularly inspected and maintained. Provide adequate welfare facilities.
Thrust Boring
Page 11 of 14
MACO-QCCP-016
QA/QC PLAN
REF.
Hazard
PERSONS AFFECTED
Initial Risk L S R
Resultant Risk S R
15
Electrocution
Operators
9 Only trained welders to use welding equipment and carry out welding operations. Ensure adequate and correct grounding is utilized prior to operating welding units. Ensure all power cables are connected by trained electricians and all connection points are locked off. Wear rubber gloves when handling any TBM connection cables during pipe change-overs. Protect all connection sockets from water during pipe change overs.
Labour and Plant
Labour:
Job Function Training PPE Comments
Supervisor
Engineer
General Labours
Plant Operators
Hard Hat First Aid Safety Boots Induction High Visibility Clothing Eye Protection Hard Hat First Aid Safety Boots Induction High Visibility Clothing Use of CAT Detector Eye Protection Ear Protection Hard Hat Safety Boots First Aid High Visibility Clothing Induction Eye Protection Use of Fire Extinguishers Ear Protection Anti Vibration Gloves Hard Hat Safety Boots Certified as trained. High Visibility Clothing Induction Eye Protection Ear Protection Anti Vibration Gloves
First Aid Training to be given to 1 in 10 persons. Use fire Extinguishers, training to be given to 1 to 10 persons.
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MACO-QCCP-016
QA/QC PLAN
Plant:
Item Description Quantity Supplier Certification Required Special Requirements / Comments
Small Tools
Variable
Hire / AJECT
No
Daily inspection before use. Weekly recorded inspection. Vibration tools regularly maintained.
Crane
1 No.
Manar Arabian Corp.
Yes
Daily inspection before use. Weekly recorded inspection. 12 monthly thorough examination. 6 months if used for manriding Height restrictor where required.
Manrider
1 No.
AJECT
Yes
Daily inspection before use. Weekly recorded inspection. 6 monthly thorough examination. Daily inspection before use. Weekly recorded inspection. 6 monthly thorough examination. Daily inspection before use. Daily inspection before use. Daily inspection before use. TBM checked before delivery to site, all electrical connection to be checked prior to use.
Lifting Chains and Equipment Weld Set Burning Equipment Generator Iseki TBM
Variable
Manar Arabian/AJECT
Yes
1 No. 1 No. 1 No. 1 No.
AJECT AJECT AJECT AJECT
No No No No
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Page 13 of 14
MACO-QCCP-016

DOCUMENT TITLE:
PROCEDURE FOR: WIRES AND CABLES
DOCUMENT NO.: MACO-QECP-001

Index 1 2 3 4 5 6 7 Page Purpose Scope References Materials Procedure Inspection & Testing Documentation 2 2 2 2 6 7 8-12
001 ISSUE NO.
04/09/09 ISSUE DATE
MACO-QECP-001 DESCRIPTION
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Wires and Cables
Page 1 of 12
MACO-QECP-001

WIRES AND CABLES

1 Purpose: 1.1 The purpose of this document is to define and establish systematic method or process to identify laid and test wires/cables, associated with electrical installation in industrial and non-industrial facilities. 2 Scope: The wires/cables covered under this scope are as follows: 2.1 Low voltage jacketed cables rated 600/1000V. 2.2 Low voltage unjacketed insulated wires rated 600V. 2.3 Medium voltage power cables, rated 5KV through 35KV to be used on system with nominal voltages above 2KV up to 34.5KV. 3 References and Standards:
Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: NEC (National Electrical Code) Royal Commission Standards
Material: 4.1 General Requirements 4.1.1 Low voltage cables/wires. 4.1.1.1 Low voltage jacketed cables shall comply with NEC or IEC 502.
Wires and Cables
Page 2 of 12
MACO-QECP-001

4.1.1.2 NEC type low voltage cables shall be rated 600V and shall have minimum temperature rating of 90 Deg. Dry/75 Deg wet and shall conform to UL standards. 4.1.1.3 IEC 502 type cables shall be rated 600/1000V and shall have a minimum rating of 85Deg. C. 4.1.1.4 NEC type low voltage unjacketed insulated wires shall be rated 600V and shall have a temperature rating of 90 Deg. C dry/75 Deg. C wet. 4.1.1.5 Low voltage unjacketed, SSA 55 type wires shall be rated 450/750V and shall have a minimum rating of 85Deg. C. For wiring of lighting fixtures, etc., the above minimum temperature is increased. 4.1.1.6 Power and control conductors shall be stranded copper, except solid conductors 6mm square (10 AWG) or smaller may be used in non-industrial locations. Mineral cables and special cables for pump motor, with solid conductor are permitted. 4.1.1.7 Stranding shall be as per ASTM, but portable cables and motor leads shall have finer stranding as per UL standard. 4.1.1.8 Cable insulation for interior building wiring shall be THHN/THWN, except for equipment grounding conductors, which may have PVC or thermo plastic insulation. 4.1.1.9 Unless otherwise indicated the minimum size of conductor for power shall be 4mm square and control shall be 2.5mm square. 4.1.1.10 Conductors of multi-conductor control cables shall be numbered or color coded by colors other than green, green with yellow stripes, white or gray. 4.1.1.11 The insulation and jacket for direct buried cables shall be cross linked polyethylene (XLPE) and polyvinyl chloride (PVC) and outer sheath jacket. 4.1.1.12 The following cables shall be permitted for cable tray system: Mineral insulated metal sheathed cable. Armored cable
Wires and Cables Page 3 of 12 MACO-QECP-001

Metal clad cable Power limited tray cable Multi conductor service entrance cable Power and control tray cable Non metallic sheathed cable, XLPE insulated type Other multi conductor control, signal or power cables, approved for installation in cable trays. 4.1.1.13 Cable shall be marked at intervals not exceeding 24 inches indicating the maximum working voltage, type of insulation, size and number of conductors. 4.1.1.14 The instrumentation and signaling cables shall be copper conductor, aluminum shielded & polyethylene insulated type. 4.1.2 Medium Voltage Power Cables 4.1.2.1 Medium voltage power cable shall be manufactured and tested in accordance with standard IEC60502-2. 4.1.2.2 Insulation material shall be cross linked polyethylene (XLPE) or ethylene propylene rubber (EPR). 4.1.2.3 Conductor and insulating screening is required for all cable. 4.1.2.4 Conductor screening shall be easily removable from the conductor and shall consist of a layer of extruded semi conducting compound. 4.1.2.5 The extruded semi-conducting conductor shield, the insulation and the semi conducting insulation shield shall be applied by simultaneous triple extrusion. 4.1.2.6 The metallic part of the insulation screen shall consist of copper tape, 5mil thickness applied with 20% overlap. 4.1.2.7 Fillers shall be used in order to render the cable free from voids. 4.1.2.8 All cables shall have continuous overall outer nonmetallic sheaths. The outer sheath shall be PVC and rated for 90oC maximum temperature.
Wires and Cables
Page 4 of 12
MACO-QECP-001

4.1.2.9 The cable shall meet the flame retardant test. 4.1.2.10 Cable shall be suitable for direct burial, above grade rigid steel conduit and cable trays. 4.1.2.11 The nominal thickness of insulation and field test voltages of 5, 15, & 35KV are given below:
System Voltage, KV (4.6) 5 (13.8) 15 (34.5) 35 Nominal Ins. Thickness 3.4 mm 5.5 mm 9.0 mm Field Test Voltage, KV 36 64 100
4.2
Manufacturers Materials are selected purely on the basis of the clients choice, subjected to compliance with project requirements, installation methods and the types of race ways used for installation. The cables/wires from the following manufacturers are used, if the client is not specific about any material from a particular manufacturer. 4.2.1 Saudi Cable Company 4.2.2 Riyadh Cable Factory 4.2.3 Middle East Specialized Cable Company 4.2.4 Other Equal manufacturers.
4.3
Material Description The following types of wires/cables are normally used for different Electrical installations. These materials shall comply with the materials and specifications defined in NEC. 4.3.1 Rubber insulated wires and cables. 4.3.2 Thermo plastic insulated wires. 4.3.3 PVC-insulated cable with circular copper conductor. 4.3.4 Thermo plastic insulated cable, 0 to 35KV.
Wires and Cables
Page 5 of 12
MACO-QECP-001

4.3.5 Cross linked thermosetting polyethylene wire and cable for the transmission and distribution of electrical energy. 4.3.6 Ethylene-propylene rubber insulated wire and cable for the transmission and distribution of electrical energy. 5 Procedure: 5.1 All cables and wires are visually inspected for any damage before installation. 5.2 Identify each wire in junction boxes, terminal boxes, cabinets and termination boxes by slip-on markers. 5.3 Conductor shall be continuous between outlets, boxes, devices etc. there shall be no splices or taps within a conduit or conduit body. 5.4 Conductors of light, control and power systems of 120, 208, 220, 380 and 480V shall be permitted to occupy the same enclosure, conduit, or tray where all conductors are insulated for the maximum nominal circuit voltage rating of any conductor within the enclosure. 5.5 All phases of a three phase circuit and a neutral wire, if any, and ground wire shall be located in the same metallic conduit when steel conduit is used. 5.6 All splices shall be made in junction boxes or splice boxes only. No splices shall be made in, L or C type fittings. Wire in conduit shall be continuous 5.7 No wire shall be pulled into conduit that terminates in major switch gear, control centers, etc., until such equipment has been installed and permanently secured in place. 5.8 An adequate length of cable or wire shall be left after pulling to make all necessary splices and terminations. 5.9 Basket grips shall be securely fastened to the cable before pulling. The area covered by the basket grip shall be removed before termination. 5.10 Cable shall be pulled faster than 50 ft per minute and slower than 15 ft per minute.
Wires and Cables
Page 6 of 12
MACO-QECP-001

5.11 Cables shall be continuously trained into the duct or conduit in such a manner that the cable will not drag on the edge of the conduit. 5.12 Lubricant shall be applied as necessary to reduce pulling friction.
5.13 Single core conductor cables shall be color coded throughout their length. Ground wire shall always be green strip and neutral shall be white or gray. Power wires shall be black, red blue, brown, black, yellow etc. Identify neutral in a multi-conductor cable by tape. Where tape is used, it shall cover 150mm of the cable. 5.14 Installed splices shall have equal or better mechanical strength and insulation as the factory insulation. 5.15 When conductors are connected in parallel, in raceways or cable trays the conductor shall be installed in groups consisting of not more than one conductor per phase or neutral, to prevent current unbalance due to inductive reactance. 5.16 Mark wires consistently throughout the system using notation of wire given. 5.17 Coordinate cable installation with other work. 5.18 Direct buried cables that cross under paved road, railroad etc. shall be run in duct bank. 5.19 Splicing for medium voltage, (2KV to 35KV) shall be carried out by trained certified technician. The materials for splicing shall be selected for the particular type of cable and all related work is performed as per manufacturers instructions. 5.20 For 2KV to 35KV installations the creepage distance between terminals are maintained as per relevant standards. 5.21 For medium voltage connections to elbows such as elastimold connectors, follow manufacturers instructions strictly. 5.22 For higher voltage installation thermo plastic insulating compounds are not acceptable.
Wires and Cables
Page 7 of 12
MACO-QECP-001

Inspection & Testing: 6.1 Low voltage cables (600, 450/750, 600/1000 V rated) including splices shall be 500/1000V megger tested after installation and prior to placing in service. 6.2 Medium voltage cables (5-35KV) and splices shall be 5KV megger tested and then DC higher potential tested after installation and prior to placing in service. The test voltage for different systems shall conform to NEC standards. 6.3 Inspection and testing shall be performed in accordance with the code and client specifications.
7 7.1 7.2 7.3 7.4
Associated Documents Wires/Cables Installation Checklist Insulation Resistance Test Continuity Test Report Hipot Test for Medium Voltage Cable QECP-001-01-WC QECP-001-02-WC QECP-001-03-WC QECP-001-04-WC
Wires and Cables
Page 8 of 12
MACO-QECP-001

WIRES/CABLES INSTALLATION CHECKLIST
QECP-001-01-WC
CONTRACT: LOCATION: CABLE NO: DRAWING NO.:
_____________________ _____________________ _____________________ _____________________
REFERENCE: PROJECT: SYSTEM: AMB. TEMP.
_________________ _________________ _________________ _________________
S.NO. 1 2 3 4 5 6 7 8 9 10 11
INSPECTION POINTS Check type, size and proper installation. Check the routing with cable schedule and drawing. Check the preparation for pulling. Check the pulling tension as per the specifications. Wires/cables identified at both ends. Cable properly supported/trained.
All conductors of phase and neutral in the same raceways.
ACCEPT
REJECT
N/A
Enough length is left for splicing and terminations. Total number of wires pulled in raceways conform as per specifications. For medium voltage cable laying and termination creepage distance. Color coding done as per standard.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Wires and Cables
Page 9 of 12
MACO-QECP-001

INSULATION RESISTANCE TEST
QECP-001-02-WC
_____________________ _____________________ _____________________ _____________________
_________________ _________________ _________________ _________________
Equip. Tag / Cable No.
Ph. A to G
Ph. B to G
Ph. C to G
Ph. A to B
Ph. B to C
Ph. C to A
REMARKS
Test Instrument details: _________________________________________________________

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Wires and Cables
Page 10 of 12
MACO-QECP-001

CONTINUITY TEST REPORT
QECP-001-03-WC
_____________________ _____________________ _____________________ _____________________
_________________ _________________ _________________ _________________
CABLE NO.
CORE ID/NUMBER
CONTINUITY YES NO
REMARKS
Test Instrument details: _________________________________________________________
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Wires and Cables
Page 11 of 12
MACO-QECP-001

HIPOT TEST REPORT (DC) FOR MEDIUM VOLTAGE CABLE
QECP-001-04-WC CONTRACT: LOCATION: CABLE NO: DRAWING NO.: _____________________ _____________________ _____________________ _____________________
1-G MICRO AMPS.

2-G MICRO AMPS.
_________________ _________________ _________________ _________________

3-G MICRO AMPS.
PHASE LEAKAGE CURRENT KV KV KV KV KV KV 15 SEC 30 SEC 45 SEC 1 MIN 2 MIN 3 MIN 4 MIN 5 MIN 6 MIN 7 MIN 8 MIN 9 MIN 10 MIN 11 MIN 12 MIN 13 MIN 14 MIN 15 MIN
Rated Voltage of Cable: _________________________________________________________

Remarks: _______________________________________________________________________ ____________________________________________________________________________________
Wires and Cables
Page 12 of 12
MACO-QECP-001

DOCUMENT TITLE:
PROCEDURE FOR: GROUNDING SYSTEMS

Index 1 2 3 4 5 6 7 8 Page Scope References Materials Quality Control Procedure Instrument Earthing Testing Documentation 2 2 2 2 3 3 4 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Grounding Systems
Page 1 of 5
MACO-QECP-002

GROUNDING SYSTEMS
1 SCOPE This procedure covers the inspection procedure pertaining to the installation for General Electrical & Instrumentation Earthing System. This procedure shall be applied to the inspection, method and criteria for installation work carried out by the Electrical Department. 2 REFERENCE STANDARDS AND CODES a) SAES-P-100 b) SAES-P-104 c) SAES-B-068 d) SAES-P-111 e) NEC 3 MATERIALS CONTROL a) b) Ensure that materials and equipment are handled in accordance with SAES-1023. Checked all supplied materials are in conformance with Purchase Order any discrepancies shall be reported immediately to MACO Materials Dept. Store all grounding materials for terminations, splicing etc. on a safe place, free from dusts and protected against atmosphere action and dirt. Lighting Wiring Methods & Materials Electrical Area Classification Grounding National Electric Code
c)
4 QUALITY CONTROL 4.1 a) CHECK/INSPECT FOR THE FOLLOWING Grounding conductors shall be soft drawn copper unless specified on detailed drawings. Direct buried grounding conductors connecting to the equipment to the ground grids maybe un-insulated or green PVC insulated.(these grounding conductors do not substitute grounding conductors required by SAEP-P-111 Para 6.3,ReferenceSAEP-P111,Para 5.1 & 5.2) Grounding grid conductors shall be a minimum of 70 sq. mm. (#2/0AWG) bare copper conductors shall be used whenever soil resistivity is less than 70 ohmmeter. Ref SAES-P-111,Para.4.2.1 All exposed non-current carrying metal parts of equipments and other sizeable metallic objects such as fences, piping, piping supports,
Page 2 of 5 MACO-QECP-002
b)
c)
Grounding Systems

d)
e) f)
motors, electrical panels , switchgears, MCCs , fixtures, grounding terminals of each receptacle, conduit metal tanks and pumps ,shall be potentially bonded to grounding grids accordingly. Conduits, cable tray, cable wire armour, or cable shields shall not be the sole means of grounding equipment. Separate grounding conductors shall be installed within the same conduit, cable tray or otherwise shall accompany with the power conductors. Metallic conduits cable trays shall be grounded at both ends of points. Reference SAES-P-111,Para 6.3 Check that installation of materials does not conflict with other services or equipment and installed as per Manufacturers recommendations. All buried or concealed connection and splices for the grounding system shall be inspected and approved by Saudi Aramco Inspector before concealment
5 INSTALLATION 5.1 a) EARTHING OF ELECTRICAL EQUIPMENT Installation shall be in accordance with ANSI/NFPA 70 and the site soil resistivity shall be measured in accordance with IEEE 81, and in conformance with SAES-P-111. Ground rods locations will be checked against the layout drawings to ensure correct positioning 1)Where rods are to be Hand driven ,the procedure will be witnessed to ensure the correct depth or Refusal is achieved .Where rods to be installed in pre-drilled bore holes, the bore holes will checked to ensure the correct depth is achieved and the backfill materials are as per specification. 2) Upon completion, the installation of the earth pit and the ground rod termination and disconnect facilities will be checked against the installation details. The location of the earth bus bars will be checked against the layout drawings and the assembly checked to ensure the fixings is secure. Underground based joints or cad welds connections will be inspected to ensure good mechanical and electrical bonding Equipment will be inspected to ensure the earth bonding facilities are installed and located as per the drawings. Particular attention will be paid to equipment, such as floating roof tanks, which require special devices. The bonding points on gates etc., which are subject to frequent movement ,will be inspected to ensure the fixing is secure The termination of the earth cables will be inspected to ensure the crimpling thermite welding and/or bolting is secure and where applicable, protected against corrosion
b)
c) d) e)
f)
Grounding Systems
Page 3 of 5
MACO-QECP-002

6 INSTRUMENT EARTHING Instrumentation and control systems require a clean Clean earth connection, completely isolated from the plant main earthing system, to prevent electrical interference on the signals being transmitted. Where Zener diode barriers are installed in intrinsically safe circuits a similar isolated, low resistance and path to earth is required. a) Instrument ground locations will be checked against relevant layout drawings to ensure correct positioning and spacing from sources of interference and installed as in item 1.5.1(b1)(b2) b) Instrument earth bars will be checked against the layout drawings and installation details c) Control panel earth reference bars will be megger checked to ensure they are isolated from the main electrical earthing ground. d) Instrument earth cables from the ground rod to the bus bar will be checked to ensure the earthing facilities and connection is as per the detailed drawings. Special attention shall be paid to the earthing of shielded conductors. Continuity throughout will be checked .Particularly where intermediate junction boxes are installed and single point earthing will be checked to eliminate the possibility of circulating currents. Where low power equipment is installed such as thermocouples ,the earth connected will be checked against the detailed hook-up drawing 7 TESTING a) The earth electrode resistance will be checked by the fall-of potential method, using megger type DET 3 or equipment hand cracked test instrument. The apparent ground resistance shall be obtained by means of a made electrode. The electrode should be installed specifically for grounding purposes. Industrial locations ,ground resistance of the made electrode shall not exceed 2 ohms for system above 600 and shall be determined in accordance with touch and step potentials as defined by IEEE80.Reference SAES-P-111,Para 4.1.4 The test method as specified for the above instrument for individual and electrode networks will be applied as follows: 1) Prior to testing the electrode system will be disconnected from the ground network. 2)The current spike will be driven to 1meter depth at a point 50mts from the perimeter of the electrode network and the potential spike driven midway, in a straight line between the current and the connection to the electrode network. 3) The terminals C1 and P1 of the instrument will be connected to the electrode system 4) Terminal C2 will be connected to the remote current spike. 5) Terminal P2 will be connected to the remote potential spike.
b)
c)
Grounding Systems

d)
e)
f)
6) The first megger reading R1 is recorded. 7) The potential spike will be moved to the point 6 meters closer to the electrode network and the reading R2 recorded. 8) The potential spike will be moved to the point 6 meters further away from the electrode network and the reading R3 recorded. 9) The potential spike will be compared and providing they have reasonable agreement the average value will be calculated to network earth resistance value For large ground works, it may be necessary to locate the current and potential electrodes in considerable distance from the connection to the network .In this instance, the current and potential electrodes can be placed at a minimum angle of 90 degrees. The test will be conducted as in item (c) with the following electrode spacing: 1) The current and potential electrodes will be driven at a distance of 300 meters from the connection to the earth network and the reading recorded 2) The current electrode will be removed out in 30meters steps and the resistance value measured until the same reading is obtained at three successive locations. The results obtained will be compared to those specified; the following will be used as a guide Plant earthing system with - Less than 1ohm extensive network Individual electrical equipment Or small networks - Less than 4 ohms Lighting and static discharge Networks - Less than 7 ohms The test will be conducted by the Site Electrical Supervisor, witnessed and recorded by the Site Electrical QC Inspector
8 DOCUMENTATION Form QECP-002-01-GS -Field Inspection Checklist Form QECP-001-01-GS -Field Test Records
Grounding Systems
Page 5 of 5
MACO-QECP-002

DOCUMENT TITLE:
PROCEDURE FOR: LOW AND MEDIUM VOLTAGE INSTRUMENTATION CABLES

Index 1 2 3 4 5 Page Scope 2 References and Codes 2 Material Control 2 Pre-Installation Test 2 Documentation 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Low and Medium Voltage Instrumentation Cables
Page 1 of 4
MACO-QECP-003

LOW AND MEDIUM VOLTAGE INSTRUMENTATION CABLES

1 SCOPE 1.1 This procedure covers the inspection and test procedures pertaining to the installation of low and medium voltage test cables 1.2 The procedure shall be applied for inspection, methods and criteria for installation work carried out by the Electrical Department. 2 REFERENCE STANDARDS & CODES a) b) c) d) e) f) g) h) SAES-P-100 SAES-P-104 SAES-B-068 S.A.G.1.2.705 NEC SAES-J-902 15.5 SAMMS-502 34-SAMSS-913 Basic Power System Design Criteria Wiring Methods and Materials Electrical Area Classification. (For splicing /Terminations) National Electric Code Electrical Systems for Instrumentation MV Power cable 5 KV-35KV Instrumentation and Thermocouple Cable
3 MATERIALS CONTROL 3.1 Ensure that cables are handled in accordance with Electrical Procedures and Material Control System requirements. 3.2 Check all cables received for conformance with purchase order /specification requirements and mechanical damage .Any damage or discrepancies shall be recorded and reported immediately . 3.3 Store all cables in safe place, free from dust and direct sunlight exposure 4 PRE-INSTALLATION TEST 4.1 All cables shall be tested on the reels prior to removal to the work site as follows : 5-15KV Cables - 5000 Volts DC 0-600V Cables - 1000 Volts DC 4.1.1 The continuity of each conductor shall be checked. Record results on form.
Page 2 of 4
MACO-QECP-003

4.1.2 The insulation resistance between conductors and between individual conductors and shield armoring if applicable shall be checked. Record only the minimum reading for each use the following test voltage. 4.2 The results shall be recorded on form checked against the values shown in Table. 4.3 After completion of test, the ends of the cables shall be sealed to prevent the ingress of moisture. 4.4 The test will be conducted by the Electrical Supervisor witnessed by the QC Inspector; Checked and signed by the QC Supervisor and Electrical Engineer; and reviewed by the Proponent Inspection. 4.5 Certificate issued by the approved testing agency 4.6 Ensure that all testing equipment has a current calibration. 4.1 a) INSTALLATION Prior to installing cables in trenches ,dust banks ,cable trays or conduits, ensure that these have been thoroughly inspected ,respective ITPs complied with documentation completed. Nylon cable ties shall be used to fasten cables to tray rungs. Outdoor cable ties shall be black, resistant to ultra violet radiation. A suitable pulling compound shall be used while cables being installed in conduits or ducts. Wiring shall be identified at termination points by the use of permanently embossed wire markers of heat shrinkable on Slip-on type. Wrap around rigid Snap-on or adhesive type markers are not permitted. Throughout the cable pulling process the Site Electrical Supervisor shall ensure that when a cable winch is used, the manufacturers permissible pulling tension values will be adhered to. Where cables of different voltage levels and /or services are run in parallel; Segregation will be in accordance with the SAES-P-104 & SAES-J-902. Splicing , glanding and terminating of medium voltage cables will be carried by cable splicers to Proponent Standards.
b)
c)
d)
e)
f)
g)
Page 3 of 4
MACO-QECP-003

4.2 a)
TESTING On completion of cable pulling and, where installed in trenches, prior to backfilling all cables will be tested for continuity and insulation resistance and the results recorded on form. Medium voltage rated from 5KV to including 15KV shall be (DC high voltage) tested after completion of jointing, glanding and end terminations in accordance with SAES-P-104, Section 13, manufacturers recommendations and 16-SAMSS-502.Results shall be recorded on Proponent Form. After completion of the tests, the cable ends shall be sealed to prevent ingress of moisture. The test result will be checked and signed off by the Engineer, Electrical Engineer and Proponent project inspection. Ensure that all test equipment has current calibration certificate issued by approved testing agency.
b)
c)
d)
e)
5 DOCUMENTATION a) b) c) d) e) Form QECP-003-01-LM Form QECP-003-02-LM Form QECP-003-03-LM Form QECP-003-04-LM Form QECP-003-05-LM
Page 4 of 4
MACO-QECP-003

DOCUMENT TITLE:
PROCEDURE FOR: SWITCHBOARDS / PANELBOARDS

Index 1 2 3 4 5 6 7 Page 2 2 2 3 3 5 5
Purpose Scope References Materials Procedure Inspection Associated Documentation
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Switchboards and Panelboards
Page 1 of 6
MACO-QECP-004

SWITCHBOARDS & PANELBOARDS

1 Purpose: The purpose of this document is to describe and approve systematic method for the installation of low voltage switchboards and panel boards in industrial areas as well as in non-industrial areas. 2 Scope: This document covers installation of switchboards and panel boards in various facilities. 3 References and Standards:
Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: NEC (National Electrical Code) ( NFPA 70 ) ANSI American National Standards institute Saudi Aramco Engineering Standards ( SAES ) Saudi Electric Company Engineering Standards ( SES ) SAES - B 068 Electrical Area classification SAES - P 100 Basic power System design criteria SAES - P 104 wiring Methods and Materials SAES - P 114 Power System and Equipment protection SAES - P 116 Switchgear and Control Equipment SES - B 119 Basic Design Aspects Saudi Aramco Material System Specifications ( SAMSS ) Saudi Electric Company Material System ( SMSS ) 16- SAMSS-518 Low Voltage Panel Boards. 16- SAMSS-519 Industrial Switchboards, Low Voltage. 31- SMSS Low Voltage Panel and Enclosures.
Page 2 of 6
MACO-QECP-004

Material: 4.1 Manufacturers Materials are selected purely on the basis of client's specification and choice, subject to compliance whit Project requirement and area of classification. The products shall be procured from any of the following Manufacturers, if the client is not advising to use Materials from particular manufactures. WESCOSA Westinghouse Electric Company. General Electric. Square D Company. ABB Any other Manufacturers approved by the client.
4.2 General Requirements / Materials specifications : Conductors and busbars in switchboards and panel boards shall be located so as to be free from physical damage and shall be held firmly in place. The arrangement of busbars and Conductors shall be such as to avoid overheat due to inductive effects. Each switchboards or panel boards, if used as service equipment , shall be provided with a main bonding jumper size in accordance with NEC standards placed within the service disconnect section for connecting the grounded service conductor on its supply side to the switchboards or panel boards frame in switchboards or panelboards loud terminals for field wiring shall be located so that it is not necessary to reach across or beyond a non- insulated ungrounded line bus. The phase arrangement on three phase buses shall be A,B,C from front to back, top to bottom or left to right as viewed from the front of the panelboards or switchboards. The panels of or switch boards shall be made of moisture resistant, non-combustible Materials. Busbars shall be insulated or bare and shall be rigidly mounted. Component parts like switches, fuses and fuse holder used on panelboards shall comply with requirement as per NEC article 204 and 404.
Page 3 of 6
MACO-QECP-004

Enclosure for panelboards shall have the top and bottom wire bending space sized in accordance with NEC standards. The minimum distance between bare metal parts, bus switchboards and so forth shall comply with the NEC. Lifting device shall be provided in the room where panelboard and switchboards are installed, if any of the withdraw-type components weighs more than 20 Kg. The interrupting rating of equipment shall not be dependant upon the upstream interrupting device rating. Voltmeter monitoring the incoming bus system to switchboards and panelboards shall be connected to the load side of the main incoming switch or circuit breaker. LV molded case circuit breaker shall have minimum trip rating of 20A ; however exception is there for smaller trip rating, if necessary, to meet the motor branch circuit protection requirement as per NEC article 430.
Procedure: Unobstructed horizontal space in front, for switchboards and panelboard shall be 1.5 meter and 1 meter respectively. Cable shall not be used to extend the main bus of switch boards and panel boards. Switch boards that have expose live parts shall be located permanently in dry location and accessible only for qualified persons for supervisions. When Switch boards and panelboard are installed in wet location or outside of the building, they shall be enclosed in a weather proof enclosure. Switch boards and panelboard shall only be used for low voltage applications. Switch boards shall only be used to distribute electricity with nonindustrial facilities. Switch boards shall not be installed in a back to back configuration. Switch boards shall only be used for a current rating of maximum 2000 amps. Never install more over current device than that the number for which the panelboard was designed, rated and approved. Panelboard shall be equipped with a minimum of 10% space & spare breakers. Not more than forty-two over current devices (other than the provided for mains) of lighting and appliance branch circuit panelboard shall be installed in any one cabinet.
Page 4 of 6
MACO-QECP-004

Panelboard used in industrial facilities shall be rated maximum of 400 Amps or less. The total load on any over current device located in a panel board shall not exceed 80 percent of the rating of it. Panelboard in damp or wet locations shall be installed to comply with relevant NEC standards. All circuit details shall be legibly identified on a circuit directory located on the face or inside of the panel door in the case of a Panelboard, and at each switch on a switchboard. For other than totally enclosed switch board, a space not less than 900mm shall be provided between the top of the switch board and any combustible ceiling. Instruments, meters and instrument transformers located on switch board shall be grounded as per NEC article 250-170 to 178. Panelboards shall be mounted in cabinets, cut out boxes or enclosures designed for the purpose and shall be dead-front. As externally operable type shall be permitted where access is only for qualified persons.
INSPECTION: Prior to energizing the circuits, test all incoming and out doing cables for electrical continuity, and for short circuits. Ensure proper connections with color coding for the 3phase system. Inspect for proper grounding of the solid neutral to the ground grid. Inspect for proper grounding of the equipment body grounding. Check for terminal connections done with proper torque as per manufacturer's instruction. Inspection and testing shall be performed in accordance with the code and client specifications.
Associated Documentation Switchboard / Panelboard installation Check List QECP-004-01-SP
Page 5 of 6
MACO-QECP-004

SWITCHBOARDS AND PANEL BOARDS
QECP-004-01-SP
CONTRACT: LOCATION: CABLE NO: DRAWING NO.: SI. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
_____________________ _____________________ _____________________ _____________________
REFERENCE: PROJECT: SYSTEM: AMB. TEMP. ACCEPT
_________________ _________________ _________________ _________________ REJECT N/A
INSPECTION POINTS
Confirm the material as per Project Requirement and see any Damage. Check panelboard/ switchboard and enclosures Comply with area of classification as per standard Check size of main incoming feeder cable. Check size of branch circuit cables. Wires/cables identified by tagging at terminations Check for proper grounding connection to the ground grid Check for equipment body grounding Check for protective devices connected in the up stream side as per drawing. Check for updated panel board schedule ( circuit directory ) affixed on the equipment door Check in front of panel board/ switch board empty space for easy access Check branch circuit space and spares, for a minimum of 10% Total numbers of over current devices not to exceed 42 (for lighting and appliance branch circuit panelboards ) Check wire bending space in terminal& top and bottom gutters Check connected load are 80% of over current device rating
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Page 6 of 6
MACO-QECP-004

DOCUMENT TITLE:
PROCEDURE FOR: INSTRUMENT WIRING

Index 1 2 3 4 5 6 7 Purpose Scope References Materials Procedure Lay-Up Procedure Documentation Page 2 2 2 2 3 5 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Instrument Wiring
Page 1 of 9
MACO-QECP-005

INSTRUMENT WIRING
1 Purpose: The purpose of this document is to define and approve systematic method or process to accomplish the electrical wiring system for instrumentation generally employed in process industries.
Scope: This document is applicable for electrical wiring of in instruments used in process industries.
References:
Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: 3.1 NEC (NATIONAL ELECTRICAL CODE) 3.2 MACO-QECP-001 Wire & Cables
Material: 4.1 Manufacturers Materials are selected purely on the basis of client's choice, subject to compliance with Project requirements and standard. The products from the following Manufacturers are used for instruments wiring, if the client is not specific about any materials from particular Manufacturers. 4.1.1 Saudi Cable Co. 4.1.2 Riyadh Cable Co. 4.1.3 Middle East Specialized Cable Co. 4.1.7 And other approved Manufacturers 4.2 Materials details & conformance: Six general groups of cables are used for instrumentation wiring which are coming under instrumentation and thermocouple cable categories. They are given below,
Instrument Wiring
Page 2 of 9
MACO-QECP-005

4.2.1
4.2.2
4.2.3 4.2.4
4.2.5
4.2.6
4.2.7 4.2.8 4.2.9
Group-1, single twisted pair/Triad, unshielded. Stranded circular copper conductor, 16 AWG size, XLPE insulation, 300 V type PLTC cables, 600 V for type TC cable, color coded, black- white for pair, black white and red for triads, with PVC jacket material. Group-2 single twisted pair/Triad shielded, with all specifications of group-1 plus shielded material of Aluminum foil bonded to nonhygroscopic polyester tapes. Group-3 multi pair/triad, unshielded, with or without overall shield, same specifications of Group-1&2 and multi pair/triad. Group-4 multi pair/triad, individual and over all shield, all Specifications of group 1,2 and 3 and added overall shield material of aluminum foil bonded to Mylar tape. Thermo couple extension wire, 16 AWG for single pair and 18 AWG for multi pair, primary insulation of XLPE & XLPO, voltage rating 300 V, with individual shield and over all shield of aluminum foil bonded to Mylar tape with PVC jacket. Group-6 fire proof cable. When the instrument installation is required to be fire proofed, silicon dioxide magnesium oxide insulated cables, as well as fire resistant polymer alloy jacketed cable meeting the fire test shall be considered. For direct buried use manufacturers certification for direct burial is required. For oil resistant purpose manufacturer shall certify that all cable is resistant to hydro carbon oil. Cables outer jacket shall be marked conductor size, number of pairs, voltage rating, type of cable, listing, sun light resistant and direct burial etc.
5.0
Procedure: 5.1 All instrument wiring shall be done as per projects dawning and comply with electrical standards and suitable MACO electrical procedures. All connections at the field instrument shall made on terminal blocks. Instrument with integral terminal blocks shall be connected directly to the field cable. The outer jacket of individual twisted pair/triad cables shall be left intact up to the point of termination. Drain wires and Mylar shield shall be cut and insulated with heat shrink sleeve at field instruments. Multi twisted pair/triad cable shall be cut to the appropriate length to minimize looping and flexing of the cable with in the junction box.
5.2
5.3
5.4
Instrument Wiring
Page 3 of 9
MACO-QECP-005

5.5
5.6
5.7
5.8
5.9 5.10
5.11 5.12 5.13
5.14
5.15
5.16 5.17
5.18 5.19
Each shield drain wire shall be insulated using an insertion jacket from the point where the outer jacket is removed, up to the point of termination. The outer jacket individual shielded twisted pair shall be lift intact up to the point of termination. One inch of heat shrink tubing shall be applied over the Mylar shield at the terminated end to prevent the Mylar unraveling. All process control instrumentation, PLCs, enunciators, ESD systems shall be powered by UPS system. UPS power and utility power shall not share the same cable or be routed in the same conduit. Splices are not permitted in instrumentation wiring, when wiring shall be extended, connections shall be made via terminal blocks in a junction box. Twist-on wire nut connectors shall not be used for making any electrical instrumentation connections. The minimum size of multi paired triad cable shall be 18 AWG and single pair cable shall be 16 AWG. The maximum voltage drop shall not exceed 5%. ITC cable shall not be installed on power limited circuits operating at the more than150 volts. The use of single cable tray or conduit for primary and back-up data link is not acceptable. Protection against reverse EMF shall be provided for inductive loads such as relays solenoids etc. this may be accomplished by installing a diode across the coil for DC loads. Data link, including fiber optic cables, shall be specified and installed per manufactures recommendations. Data link cables shall not be routed in the same conduit, duct, or cable tray with other instrument cable. Single twisted pair cable shall be installed in steel conduits from field instruments to the field junction box. Low point drain and breather shall be installed. The armored cable shall be routed independently of existing over head tray system. The unsupported end of the cable at the instruments should not exceed tow feet. All signal wiring shall go to marshaling box panel terminal strip. All spare pair cables shall be terminated at both the field junction bon and the marshaling panel. Drain wires for spare shielded pair shall also be individually terminated. Emergency shut down system (ESD) and fire detection system shall have dedicated cabling, junction boxes and marshaling cabinets. Cables entering the marshaling cabinets shall be cut to the appropriate length. Coiling extra cable beneath the box is not acceptable.
Instrument Wiring
Page 4 of 9
MACO-QECP-005

5.20 Instrumentation cables installed beneath computer type floors in control room shall be placed in ladders, trough or solid bottom cable tray. 5.21 Different signal categories shall be routed via segregated cabling and shall not share the same cable, conduit, junction box or try. Minimum separation requirements between various instrumentation cables shall be as per manufactures recommendations. 5.22 Signal wiring shall be installed in a manner that will minimize unwanted and unnecessary distortion of the signal. Unwanted voltages are imposed on electrical signal transmission system by inductive, capacitive or coupling with other circuits by leakage current. 5.23 Shielded cable shall be used to reduce electro static noise. The Shield shall be grounded at one point only at the marshaling panel. Cable shields must have a single continuous ground path. 5.24 Twisted pair/triad cables shall be used on all instrument loops to reduce spurious signals resulting from induced voltage. 5.25 Terminals for AC, DC current service shall be grouped together but physically separated by means of dividers. 5.26 Terminals for 120VDC and 120 VAC power for field contacts shall be segregated from other system. 5.27 Terminal strip for ESD system wiring shall be completely separated from other wiring power control and instrumentation. 5.28 All wire shall be tagged at both ends. Cables entering junction box shall be marked cable numbers. 5.29 The metal equipment and enclosures with in a panel or series of panels shall be bonded with bonding jumpers and connected with safety ground bus with copper wire of 4 mm square cross sectional area. Grounding shall be done as per HKSS grounding procedure. 6.0 INSPECTION: 6.1 inspections and tasting shall be performed in accordance with the code and client specifications. 7.0 7.1 7.2 7.3 7.4 Associated Documents: Instrumentation Wiring Check List Instrument Wiring Test Report Insulation Resistance Test Continuity Test Report QECP-005-01-IW QECP-005-02-IW QECP-005-03-IW QECP-005-04-IW
Instrument Wiring
Page 5 of 9
MACO-QECP-005

Instrument Wire/Cable Installation Checklist
QECP-005-01-IW CONTRACT: LOCATION: CABLE NO: DRAWING NO.: S.NO 01 02 03 04 05 06 07 08 09 10 11 _____________________ _____________________ _____________________ _____________________ REFERENCE: PROJECT: SYSTEM: AMB. TEMP. ACCEPT
Check the cable routing with cable schedule and drawing cable routing clean and free from debris Check type and size of cable Cable is identified at both ends Check the cable pulling tension as per the specification. Check the cable preparation for pulling. UPS power and Utility power pulled in different raceways Data link and fiber optic cable pulled separate. ESD and fire detection cables shall have dedicated conduits Spare cables terminated Mylar shielding properly cut, copped & terminated
_________________ _________________ _________________ _________________ REJECT N/A
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Instrument Wiring
Page 6 of 9
MACO-QECP-005

Instrument Wiring Test Report
QECP-005-02-IW CONTRACT: LOCATION: PANEL NO: DRAWING NO.: _____________________ _____________________ _____________________ _____________________ REFERENCE: PROJECT: SYSTEM: EQUIP. NO. _________________ _________________ _________________ _________________
Electl. Signal Temperature Alarm interlock _____________
SEALING COMPOUND RESULTS NOTES INSULATION MOHM
JUNCTION BOX: ____________________________________________ CABLE NO. & SPEC. _________________________________________

FIELD INS. CABLE(1) CABLE (2) WIRE NO. JB TERM. NO. CONTROL ROOM CONTINUITY
LINE TO PANEL NO. TERMINAL
TERMINAL
TAG NO.
ITEM NO.
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
SPECS
CORE
MACO SUPERVISOR
Instrument Wiring
Page 7 of 9
MACO-QECP-005

Insulation Resistance Test
QECP-005-03-IW CONTRACT: LOCATION: PANEL NO: DRAWING NO.:

EQUIP.TAG/ CABLE NO. PH. A TO G
_____________________ _____________________ _____________________ _____________________

PH. B TO G PH. C TO G
REFERENCE: PROJECT: SYSTEM: AMBIENT TEMP.

PH. A TO B PH. B TO C
_________________ _________________ _________________ _________________

PH. C TO A REMARKS
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Instrument Wiring
Page 8 of 9
MACO-QECP-005

Continuity Test Report
QECP-005-04-IW CONTRACT: LOCATION: PANEL NO: DRAWING NO.: _____________________ _____________________ _____________________ _____________________ REFERENCE: PROJECT: SYSTEM: EQUIP. NO. _________________ _________________ _________________ _________________
CONTINUITY CABLE NUMBER CORE ID/NUMBER
YES
NO
REMARKS
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Instrument Wiring
Page 9 of 9
MACO-QECP-005

DOCUMENT TITLE:
PROCEDURE FOR: INSTRUMENT CONTROL PANELS

Index 1 2 3 4 5 6 7 Purpose Scope References Materials Procedure Lay-Up Procedure Documentation Page 2 2 2 2 3 5 5-7
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Instrument Control Panels
Page 1 of 6
MACO-QECP-006

INSTRUMENT CONTROL PANELS

1 Purpose: The purpose of this document is to describe and approve systematic method or process to accomplish the installation of instrument control panels, control cabinets, consoles & marshaling cabinets for locations in electrically unclassified air conditioned building as well as unclassified out door locations. 2 Scope: This document is applicable in the installation of instrument control panels, control cabinets, consoles & marshaling cabinets of indoor and outdoor construction related to process industries. 3 References:
Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: 3.1 NEC (NATIONAL ELECTRICAL CODE) 3.2 MACO-QECP-001 Wires & Cables
Material: 4.1 Manufacturers Control cabinets and marshaling boxes are selected purely on the basis of client's choice, subject to compliance with Project requirements and standard. The products from the following Manufacturers are used for instruments wiring, if the client is not specific about any materials from particular Manufacturers. Control panels are fabricated with accessories, components mounted in it and related wirings are carried out as per wiring diagrams in compliance with specification from approved local Manufacturers. 4.1.1 Crouse hinds 4.1.2 Hoffman 4.1.3 O.Z. Gegneys
Page 2 of 6
MACO-QECP-006

4.1.4 Himmel Cabinets 4.1.5 ABD other approved equal Manufacturers
4.2 Materials details & conformance: 4.2.1 All control cabinet equipment and wiring shall be designed for continuous operation at 50 deg C and relative humidity 80% maximum and 20% minimum. The cabinet shall be rigid and self supporting. The cabinet shall be floor or wall mounted. Indoor cabinet shall be NEMA type 1 and out door type shall be NEMA 4, 4X, 3, & NEMA 7 etc. depending area of classification and environment. Cabinet requiring heat dissipation shall be convection ventilated and shall be provided with readily accessible removable filter screens. Fan may be used with in cabinet for power supplies to assist in heat removal and for over temperature provision shall be made for external alarm annunciation. Cabinet support bracing shall not restrict maintenance access to chassis, modules or components. Each cabinet shall be provided with removable lifting rings. All doors of cabinet must be capable of swinging at least 90 deg open at the installed location. A minimum of primer under coat and finishing coat of enamel or lacquer is required. Interior cabinet color shall be white or of a light color. Where ever name plate abbreviations are avoided. Name plates shall be made from laminated plastic, information engraved into the back core. No spare cut outs shall be provided unless specified. Spare panel space shall be left accessible for future installation of instruments. Air piping material to the control panel shall be stainless steel and tube fitting shall be stainless steel and shall be compression type. Equipment which is not enclosed or hermetically sealed, but is situated off shore or near shore shall be protected from corrosion and wind born sea water spray or accumulation of wetted salt.
4.2.2 4.2.3
4.2.4
4.2.5
4.2.6 4.2.7 4.2.8 4.2.9
4.2.10
4.2.11 4.2.12 4.2.13
Page 3 of 6
MACO-QECP-006

Procedure: 5.1 Control panels shall be fabricated as per project drawing and shall conform to relevant standards and appropriate for environmental conditions. All components, accessories mounted inside the panel shall be as per client requirement and project construction drawing. No process piping of any kind shall be installed in a control cabinet. They only fluid allowed in instrument air. For out door installation the panels, materials and equipments required for electrical wiring and installation within the control panel be suitable for use in specified area. For explosion proof cabinet conduit shall have a removable blank gland plate. Elevated outdoor control cabinets shall normally have conduit entry from the bottom. For outdoor classified location install only hermetically sealed relays. Push buttons, pilot lights and switches shall be heavy duty and oil tight. All process instruments shall be powered from instrument- circuit power distribution panel. Each distribution panel shall be dedicated to single voltage level. These panels shall not give power to non instrumentation wiring. Power wiring for field instruments, two-wire analog transmission loops field switch contacts etc. shall be individually fused and provided a means of disconnecting the power without distributing terminated wiring. Wiring connected to I/O modules or interfaces containing individual current limiting do not required fuses and also low level signal wiring connected directly to I/O. Exposed electrical connections with voltage greater than nominal 48 volts AC/DC shall have removable transparent insulating plastic cover. Terminal strip spacing shall allow ample room for plastic wire ducts and shall permit training and lacing of cables. Each terminal strip shall be labeled above or below with the terminal numbers. Terminal strip for ESD wiring shall be completely separate from all other wiring including power and control. Wiring for a given instrument loop shall be terminated on adjacent terminals on the terminal strip in order to organize and group all loop wiring. Terminals of various types of general wiring, enunciator points and single wiring shall be separated by dividers.
5.2 5.3 5.4
5.5 5.6 5.7 5.8 5.9
5.10
5.11
5.12
5.13
5.14 5.15
5.16
Page 4 of 6
MACO-QECP-006

5.17 No more than two wires shall be connected each side of the single terminal block. 5.18 Plastic wire ducts with removable cover shall be installed in control panels, cabinet to provide a mean of routing and organize wiring. 5.19 Wiring shall not be threaded through undressed access hole. Glands or protective grommets shall be used. 5.20 Color coding shall be done as per standards and HKSS cable Identications procedures. 5.21 Lamps test button shall be installed for all instrument control panel. 5.22 Cable shield shall have continues path to ground. 5.23 Separate, electrically isolated grounding bars shall be provided at the bottom of the cabinet. 5.24 Cabinet lighting and convenient outlet shall be installed where practical and necessary as per projects specification. 5.25 When inductive loads are switched, suppression diodes shall be used for relay installation. 5.26 For the supply voltage of 24 VDC a tolerable 21 28.2 shall be required for 125 VDC tolerance of 113 141 VDC and 120 VAC shall be maintained. 5.27 Power supplies outputs shall be individually fused or protected by a circuit breaker. 5.28 Power supplies shall be identical when ever possible for inter changeability and spare parts requirement. 5.29 Signal categories shall not be mixed with any signal multi core cable. 24 VDC digital and 24 VCD 4-20 mA may be run in the same plastic duct but not in a signal multi core cable.
6.0 INSPECTION: 6.1 Inspection and testing shall be performed in accordance with the code and client specification.
7.0 7.1
Associated Documents: QECP-006-01-IC Instrument Control Panel Installation Checklist
Page 5 of 6
MACO-QECP-006

INSTRUMENT CONTROL PANEL INSTALLATION CHECKLIST
QECP-006-01-IC
_____________________ _____________________ _____________________ _____________________
_________________ _________________ _________________ _________________
CHECKS TO BE PERFORMED
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Check the enclosures of panels for area classification. Control panels components are as per standard and approved list. Wiring diagrams are being followed properly. Power wiring fused properly. For outdoor type relays hermetically sealed. Wires spares provided, and also spare terminal strips. General wiring and signal wiring segregated For outdoor type push buttons switches heavy duty. Cabinets supports adequate and as per standard. The only fluid connected to the panel is air. Grounding is provided as per standards. Signal and digital are not taken in common cable. Proper label tags & nomenclature.
YES
COMPLIANCE NO
N/A
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________
MACO SUPERVISOR
Page 6 of 6
MACO-QECP-006

DOCUMENT TITLE:
PROCEDURE FOR: FIRE ALARM SYSTEM

Index 1 2 3 4 5 6 Scope References Materials Quality Control Installation Documentation Page 2 2 2 2 5 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Fire Alarm System
Page 1 of 3
MACO-QECP-007

FIRE ALARM SYSTEM

1 SCOPE a) This procedure covers the inspection and test procedure pertaining to the installation of Fire Alarm Sensor, Manual Stations, local fire alarm panels and essential hard wares for the fire alarm system. b) This procedure shall be applied to the inspection, method and criteria for installation work carried out by the Electrical Department. 2 REFERENCE STANDARDS AND CODES
a) b) c) d) e) f) g) 3
NFPA ANSI OSHA NEC NEMA UL SAMSS
National Fire Protection Association. American National Standard Institute. Occupational Safety and Health Institute. National Electrical Code National Electrical Manufacturers Association Underwriters Laboratories Saudi Aramco Material Systems Standards
MATERIAL CONTROL a) All material and equipment shall be protected from damage during handling and storage. Each piece of equipment shall be tested to ensure proper operation and conformance with Manufacturers Specification before delivery. b) Fire Alarm system shall be ready to use Honeywell, Pyrotronics, Simplex or equivalent. Co-ordinate the mechanical plans to ensure proper locations of smoke and duct detectors. c) Equipment Manufacturer shall furnish wiring diagram and equipment specification submittals for clients approval prior to installation. d) All system operation shall be addressable type. e) The Fire Alarm Panel shall be intelligent, each with its arm microprocessor and capable of supporting multiple circuits. f) The Fire Alarm Panel shall provide general purpose inputs for self diagnostic functions such as low battery or AC failure and all power required for field devices connected to monitor.
Fire Alarm System
Page 2 of 3
MACO-QECP-007

g) Fire Alarm switches shall allow authorized personnel to initiate a general alarm condition ,Silence the local audible ,silence the alarm signal , disable the signal to the central fire monitor, reset all zones after all zones have returned to normal condition. Test all Leos without affecting any zone condition: estimate a device mismatch condition by changing the device type and fan shut down of HVAC within designated zones. h) All manual pulls station must be non coded spring loaded contact, non- break glass type that lock when actuated and to be normally released. i) Bell/Horn shall include an integral flashing stroke light with white polycarbonate lens and red Fire lettering. 4 QUALITY CONTROL a) The system shall be installed, connected and tested under the supervision of a qualified personnel normally engaged in this type of work for at least the past 3 years. Determine the work to be performed .Provide the type and amount of materials and equipments necessary to place the work in proper location. Complete installation, wire tested and ready to use. Check installation conforming to manufacturers installation instruction
b)
c) 5
INSTALLATION a) System wiring shall be installed and run in conduit as required by the specifications, sizes and test face grounds, open or short circuits. b) Thermal detectors shall not be installed within 3ft of an HVAC Diffuser. c) Upon completion of system installation, thorough checking of the fire alarm system should be done and instruct the clients representatives in the operation and function of the system. d) Actual locations of initiating devices signal appliances and smoke detectors shall be recorded.
6 DOCUMENTATION a) Field Inspection Checklist.
Fire Alarm System
Page 3 of 3
MACO-QECP-007

DOCUMENT TITLE:
PROCEDURE FOR: LIGHTING

Index 1 2 3 4 5 6 7 Purpose Scope References Material Procedure Inspection & Testing Documentation Page 2 2 2 2 2 3 4
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Lighting
Page 1 of 9
MACO-QECP-008

LIGHTING
1.0
Purpose: The purpose of this document is to define and establish systematic method or process to install lighting fixtures in industrial and non- industrial facilities.
2.0
Scope: The three lighting installations covered under this scope are: 2.1 Outdoor lighting fixtures 2.2 Indoor lighting fixtures 2.3 Emergency lighting fixtures
3.0
References:
Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: NEC SAES-P-100 SAES-P-104 SAES-B-068 SAES-P-123 NEMA IEEE ANSI NATIONAL ELECTRICAL CODE Basic Power System Design Criteria Wiring Methods and Materials Electrical Area Classification. Grounding System National Electrical Manufacturers Association Institute of Electrical & Electronics Engineers American National Standard Institute
4.0
Material: 4.1 general requirements 4.1.1 Fixture Locations 4.1.1.1 All fixtures installed in wet or damp location shall be marked, "suitable for wet or damp locations." Subject to saturation with water
Lighting
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MACO-QECP-008

or other liquids, location exposed to weather and un protected and vehicle washing areas etc. are wet locations. 4.1.1.2 Fixtures installed in corrosive locations shall be of a type suitable for such locations. 4.1.1.3 Fixtures shall be permitted to be installed in cooking hoods of non residential occupancies. * Fixtures shall be identified for the use and the temperature limit of the materials shall not be exceeded. * All exhaust vapors, grease, oil or cooking vapor shall be excluded from the lamp and wiring department. * wiring methods and material supplying the fixtures shall not be exposed with in cooking hood. 4.1.1.4 No parts hanging fixtures or pendant shall be located with in a zone measured 3 feet horizontally and 8 feet vertically from the top of the path tub rim. 4.1.1.5 Fixtures installed over highly combustible material shall be of the un switched type. Unless an individual switch is provided for each fixture, lamp holders shall be located at least 8 feet above the floor or shall be so located or guarded that the lamps cannot be removed or damaged. 4.1.1.6 Externally wired fixtures shall not be used in a show window. 4.1.1.7 Lighting systems shall be designed for energy efficient operation. 4.1.1.8 Direct control switches and switching contacts used on in candescent lighting circuits shall have a continuous rating of at least 1.5 times the steady state current of the lighting load. 4.1.1.9 Direct control switches and switching contacts used on fluorescent lighting circuits shall have a continuous rating of at least twice the steady state current of the lighting load. 4.1.1.10 Lighting poles and supports. 4.1.1.10.1where flood light are installed on steel towers, the tower shall be equipped with steel service platform located 1.5 meters below the fixture.
Lighting
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MACO-QECP-008

4.1.1.10.2 Poles for area lighting and street lighting in process area shall be hot-dipped galvanized steel. 4.1.1.10.3 Poles outside process shall be galvanized steel or aluminum alloy. 4.1.1.10.4 Aluminum and steel poles shall be provided with a suitable wiring compartment located at a height of 150 mm or more than 900 mm from the base. 4.1.1.10.5 The use of existing structural steel, equipment structures and building walls for mounting general area flood light fixture are desirable. 4.1.1.11 Types of Exterior and interior lighting fixtures generally used are as follows: 4.1.1.11.1 Mercury vapor 4.1.1.11.2 Metal halide 4.1.1.11.3 High pressure sodium 4.1.1.11.4 Low pressure sodium 4.1.1.11.5 Fluorescent 4.1.1.11.6 Incandescent 4.1.1.12 Applications of exterior lighting fixtures generally required are as follows: 4.1.1.12.1 Outdoor area lighting 4.1.1.12.2 Outdoor flood lighting 4.1.1.12.3 Outdoor spot lighting 4.1.1.12.4 Outdoor supplementary lighting 4.1.1.12.5 Outdoor landscape lighting 4.1.1.12.6 Outdoor security lighting etc. 4.1.1.13 For office lighting fixtures of surface-mounted, semi direct fixtures shall be ideal where approximately 10% to 30 % of light is in 90deg to 180 deg. Zone and 60% in 0 deg. Zone.
Lighting
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MACO-QECP-008

4.1.1.14 Always use fixture with overall efficiency of not less than 70% bare-lamp lumens for office lighting purpose. Construct shielding assembly of molded virgin acrylic panels in combination with not less than 20 gauge durable lacquered steel louvers, finished in high temperature. Backed white enamel, removable louver assembly with hinges for easy maintenance. The wiring channel, reflectors, covers and end plates shall be 20 gauge steel and corrosion resistant baked white enamel. 4.1.1.15 Ballasts and capacitors for fluorescent and HID fixtures shall be polychlorinated biphenyl (PCB) free. 4.1.1.16 Light fixtures shall be suitable for the environment where they are installed. The installation shall be in accordance with area classification. 4.1.1.17 Light fixtures positioned over stairways, platforms, elevated walkways and landing shall be mounted at a height of 2.03 m. 4.1.1.18 Outside area and street lighting power shall be controlled by photocells. In plant areas photocell control of area and street lighting shall be through a lighting contactor with a hand-off automatic switch and provisions for remote operation. 4.1.1.19 Source of emergency lighting power include emergency stand-by generator and station batteries. The use of Emergency light set, general purpose shall be self contained, surface/wall mounted with minimum two lamps and shall have the following features.
4.1.1.19.1 LED indictor light and test switch shall be on front panel. 4.1.1.19.2 When storage batteries are used as a source of emergency power, minimum duration of emergency during power failure shall be 1 1/2 half hours. 4.1.1.19.3 Charger shall be fully automatic, solid state type, with sealed transfer relay and fused output circuit. 4.1.1.20 ' Exit' sign emergency lighting fixtures shall be self contained with AC or battery illuminated 'exit' sign unit and down light mounted inside. Sign is illuminated by AC powered lamps under normal condition. When supply voltage drops to 80 percent of nominal voltage. Emergency lamp is illuminated by DC power and when voltage is restored, AC lamps are re lighted.
Lighting
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MACO-QECP-008

4.1.1.21 Lighting for control rooms shall be designed for maximum flexibility to permit flicker free variation of illumination levels. Fluorescent and incandescent fixture installed in control rooms shall provide shadow less illumination. 4.1.1.22 Fixtures for suspended ceilings shall be recessed shall be recessed mounted type and shall be self supported. 4.1.1.23 Fixtures having exposed ballasts or transformers shall be installed such that the ballasts or transformers will not be in contact with any combustible material. 5.0 Procedure:
5.1Exterior Lighting Fixtures 5.1.1 Install exterior lighting fixtures at locations and heights as indicated in accordance with fixture manufacturer's instructions, applicable requirements of NEC and with recognize industry practice to ensure that lighting fixture fulfill requirements. 5.1.2 Fasten electrical lighting fixtures and brackets securely to the structural supports including poles. 5.1.3 Ensure that installed fixtures are plumb and level. 5.1.4 Poles and foundations shall be strong enough to withstand wind loading. 5.1.5 Lighting pole installed within 5 meters from roads having a speed limit above 50 Km/h and up to 65 Km/h shall have a breakaway bases as per standard. Poles with breakaway bases shall not have traffic guards. 5.1.6 Provide equipment grounding connections as per drawing and in conformance with the grounding specifications. 5.1.7 Clean all lighting fixtures upon completion of installation. 5.1.8 Replace the lamps in exterior lighting fixture which are observed to be noticeably dimmed after testing, if client requests. 5.1.9 Upon completion of installation, apply electrical energy to circuitry to demonstrate the capability and compliance with requirement.
Lighting
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MACO-QECP-008

5.2 Interior lighting fixtures 5.2.1 The interior lighting fixtures shall be installed as per architectural drawings and specifications. Verify ceiling types, modules, suspension systems for compliance with the requirements and specifications. 5.2.2 Verify the installations are carried out, in such a way to dampen ballast generated noise. 5.2.3 Equip the lighting fixtures with plaster frame for installation in plaster or gypsum board ceiling and proper trim for installations in suspended acoustic tile ceilings. 5.2.4 Provide fixtures and/or fixture outlet boxes with hangers to properly support fixtures weight. 5.2.5 Install flush mounted fixtures to eliminate light leakage between fixture frame and finished surface. 5.2.6 Provide plaster frames for recessed fixtures installed other than suspended grid type acoustical ceiling systems. Brace frames temporarily to prevent distortion during handing. 5.2.7 Fasten fixtures securely to structural supports and ensure that pendant fixtures are plumb and level. Provide individually mounted pendant fixtures longer than 2 feet with stem hangers with clams. 5.2.8 Support surface mounted fixtures, greater than 2 feet in length, at a point in addition to the outlet box fixture stud. 5.2.9 Tighten connectors and terminals including screws and bolts in accordance with the equipment manufacturers torque tightening value. Provide equipment grounding connections. 5.2.10 upon completion of installations, clean interior lighting fixtures of dirt and constructions. 5.3 Emergency lighting fixtures 5.3.1 Set units plumb, square and level with ceiling and walls and secure in accordance with manufacturer's instructions and approved shop drawing.
Lighting
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MACO-QECP-008

5.3.2 Mount heights specified or indicated. 5.3.3 Recessed and semi recessed fixtures may be supported from suspended ceiling systems. Support with 4 rods or wires per fixture and locate not more than 6 inches from fixture corner. 5.3.4 Do not support fixtures by ceiling acoustical panels. 5.3.5 Where fixtures smaller than the ceiling grid are indicated to be centered in the acoustic panel, support fixtures independently with at least two3/4 inch metal channel spanning secured to ceiling tees. Install support clip for recessed fixtures. Securely fastened to grid members. 5.3.6 Coordinate with other electrical installations as appropriate for proper installation of emergency lighting fixtures. 5.3.7 Clean emergency unit light set upon completion of installation. Adjust focusable fixtures to provide light intensities in egress path. 5.3.8 Ground non-current carrying parts of the equipments. 5.3.9 Apply and interrupt electrical energy to demonstrate proper operation. Test all lamps and if mal functions any lamp replace them.
6.0
INSPECTION & TESTING 6.1 Installation resistance test is conducted before and after connection of fixtures and equipment. 6.2 Perform electrical continuity test for the wires. 6.3 Perform the illumination level test. 6.4 Inspection and testing shall be performed in accordance with code and client specifications.
7.0
Associated Documents: 7.1 Lighting Installation Check List 7.2 Lighting Circuit Test Record 7.3 Illumination level test (QECP-008-01-LS) (QECP-008-02-LS) (QECP-008-03-LS)
Lighting
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MACO-QECP-008

CONTRACT: LOCATION:
REFERENCE: PROJECT:
CONDUIT NO. : __________________ DRAWING NO. : _________________
SYSTEM: _____________________ AMB.TEMP: ___________________ N/A
S.NO INSPECTION POINTS ACCEPT REJECT 01 Check the area classification Check illumination level is enough for the 02 location as per requirements Inspect distribution box circuit number, switch 03 rating, safety feature etc Check exterior pole, foundation strong to 04 withstand wind load Spot check lamp fitting, spot check wall 05 switches and wall socket etc. Check ballast noise level for interior fixture 06 installations Check all lighting are free from dirt, free from 07 finger points and smudges from lenses Supports, clamps and supports for pendant 08 fixture are in compliance with project specification 09 Grounding as per specification 10 Lamps are checked for damage Check the circuit breaker ratings are enough for 11 fixtures 12 Photocell installed as per requirement
REMARKS: ____________________________________________________________ ______________________________________________________________________
MACO QC Inspector Signature Name date
Proponent Representative
Lighting
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MACO-QECP-008

DOCUMENT TITLE:
PROCEDURE FOR: DC POWER SYSTEMS

Index 1 2 3 4 5 6 Scope Purpose References Definitions Responsibilities Procedure Page 2 2 2 3 3 7
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
DC Power
Page 1 of 10
MACO-QECP-009

DC Power Construction Quality Control Procedure

1 Scope
This quality procedure defines the type and extent of inspections to be carried out to verify that all operations involved with DC Power Systems, and other associated installation activities are conducted and complied in accordance with governing specifications and industry practices.
Purpose
The purpose of this quality procedure is to address paragraph 4.9 of ISO 9002 Process Control for Installation of DC Power Systems, and other associated installation activities are conducted in accordance with governing specifications and industry practice. The quality control test and inspections required and approved for the work are described in this procedure. Found in the procedure and SATIP section titled Quality Control Activity is a description of the inspection and test activity to be conducted by the inspector.
References
SAEP-020: SCHEDULE Q:
Equipment Inspection Schedule Quality Assurance and Control, Inspection and Testing Basic Power System Design criteria Direct Current and UPS Systems Wiring Methods and Materials Grounding Power System and Equipment Protection Communication DC Power System
SAES-P-100: SAES-P-103: SAES-P-104: SAES-P-111: SAES-P-114: SAES-T-151:
DC Power
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MACO-QECP-009

SAES-T-795: 17-SAMSS-511: 17-SAMSS-514:
Communications Facility Grounding Systems Stationary Storage Batteries Battery Charger Rectifier
National Electrical Code National Fire Protection Association (NFPA) Standards of the National Electrical Manufacturers Association (NEMA) Saudi Government Safety and Security Directives SSD 12, 14, and 17 Applicable DC Power Drawings as identified in the project Drawing Index
Definitions
QCP: IFC: Company: MACO: IK: OOK: PID: QA/QC: RFI:
Quality Control Procedure Issued for Construction Proponent Manar Arabian Corp. (MACO) In Kingdom Out of Kingdom Project Inspection Department Quality Assurance/Quality Control Request for Inspection
Responsibilities The Site or Discipline Engineer In-Charge will be responsible for the following:
DC Power
Page 3 of 10
MACO-QECP-009

To ensure that construction/erection is carried out to the required Job Specifications and Approved Construction/Erection Plans. To ensure that the work is complete and ready for inspection and to initiate the required internal application form for inspection. Will be responsible for ensuring that all parties required to conduct joint inspection or tests are informed as to the construction program. Request for inspection originate with the field foreman through their respective discipline engineers. Upon completion of the installation activities ensure that any mark-ups to the approved drawing(s) have been completed and reflect the installed equipment properly.
The Quality Assurance Manager will be responsible for the following: Inform the Company Representatives by the official Request for Inspection (RFI) Form SA-6717-ENG when various operations are being performed. Contractor representatives will issue this form when various stages of the work are complete or in progress and can be witnessed/inspected by the Company. Ensure that approved discipline inspectors are informed of inspection schedules and are available to support the construction schedule. Ensure that the complete inspection records are maintained and filed by the organization responsible for the work Will review all relevant documentation, test reports, and Certificates, and prepare all handing over documents and clearing out all pending non conformance items. Will coordinate with discipline Quality Control Inspectors to ensure that all other discipline activities requiring inspection within the construction program have been inspected and cleared.
DC Power Page 4 of 10 MACO-QECP-009

Will sign and obtain signatures from Company representatives for document review per the various Royal Commission for Jubail & Yanbu Test and Inspection Plan (SATIP) thereby confirming that all the attachments and Inspection signatures per the various SATIPs are properly executed before the preparation of the handover documents. Organizing and allocating the various inspection tasks to the Quality Control Inspectors or in some cases, discipline engineers. At the completion of an integral part of the work, as defined by the Mechanical Completion Procedure, all quality inspection and test records for that portion will be assembled and reviewed for completeness by Manar Arabian Corp. (MACO) Quality Inspectors and Quality Assurance Manager. Assembled documents will then be turned over to Manar Arabian Corp. (MACO)Document Control. Accompany Company representatives, as required, to carry out routine inspections of release hold points by signing and obtaining representatives approval signatures per the various Royal Commission for Jubail & Yanbu Test and Inspection Plans (SATIP) as recorded proof of project work conforming to specifications. The Discipline QC Engineers will be responsible for: Ensure that the work conducted in assigned discipline is in accordance with quality and engineering standards and that the QC procedures and SATIP is followed. Prepare and submit for the QA Managers review the necessary discipline quality documentation. Implement quality control activities on site in line with the established quality control program. Supervise the QC Inspectors in performing inspections and testing, compiling records and reports.
DC Power
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MACO-QECP-009

The Discipline QC Inspectors will be responsible for: Perform or witness the inspections and test required by the respective Royal Commission for Jubail & Yanbu Test and Inspection Plan (SATIP). To this end they coordinate with the construction personnel who have the responsibility for issuing the necessary notifications to QC. Report the inspection and testing results on the inspection and test form and check sheets. Issue through the QC Engineer all request for inspection to the contractor and Royal Commission for Jubail & Yanbu. Coordinates timing and procedure. Report to the Discipline QC Engineer any nonconformance identified during inspections. Safeguard inspection documentation until submission to the Document Control Clerk for proper filing after all inspection pertaining to an MCC segment is complete. The Technical Clerk will be responsible for: Keeping daily log of all Inspection Forms Requests by Site/Section Engineers. If a technical clerk is not available, the log and inspection records will be kept by the originating quality inspection organization. Filing and compiling all inspection records and handing over documents under the supervision and instructions of the Quality Assurance Manager.
Quality Records The fundamental quality records produced for this procedure are the RFI and the associated SATIP Check Sheet. The check sheet identifies the quality control activities and all the related information from the SATIP. The sub-contractor quality control inspector initiates the check sheet for each RFI. The RFI number is reflected on the check sheet. After the subcontractor completes his inspection, the sheet is copied and attached to the RFI and given to Manar Arabian Corp. (MACO) discipline quality inspector. The Manar Arabian Corp. (MACO) quality inspector inspects the
DC Power Page 6 of 10 MACO-QECP-009

work as required by the surveillance code, signs or initials the check sheet and the RFI form. Both forms are copied for the records of Manar Arabian Corp. (MACO) and the sub-contractor, are filed. The original RFI form and a copy of the check sheet is then given to Royal Commission for Jubail & Yanbu PMT. SAPMT discipline inspector inspects the work as required by the surveillance code, signs or initials the check sheet and the RFI Form. Both RFI and check sheet are then given to HDPIS discipline inspector who signs the RFI form. The pink copy of the RFI and a copy of the check sheet are returned to Manar Arabian Corp. (MACO) for record. A copy is made for the responsible sub-contractor quality files. HDPIS inspector inspects the work as required by the surveillance code and may sign or initial the check sheet. Quality Control Activity Project quality inspectors will respond to request for inspection (RFI) throughout every stage of the construction process. This procedure and the companion Royal Commission for Jubail & Yanbu Test and Inspection Plan (SATIP) serve as a guide for the inspection work, complete with acceptance criteria and criteria reference. Paragraph numbering for this section matches the inspection activity found on the Royal Commission for Jubail & Yanbu Test and Inspection Plan (SATIP). Request for Inspection: Requests for Inspection originate with the contractor Foreman. Information on the form should be complete and legible. Based on the nature of the work item to be inspected, the inspector shall consult the SATIP, this procedure and any referenced acceptance criteria to ensure that the work is inspected for acceptability per the Royal Commission for Jubail & Yanbu and industry standards. This format provides for multiple inspection items to be covered by a single RFI. Example: A single RFI for, listed on the SATIP under that category. When submitting RFIs to cover multiple items on the ITP, foreman should reference the QCP/SATIP and applicable inspection item numbers. Check sheets for the RFI are recommended if repeated inspections for a similar nature are to be made. In some certain instances, interim inspections are required. Multiple Inspection Required is noted in the Quality Control Activity column. The inspection level for each inspection item is indicated on the Inspection Test Plan with code key reference found at the bottom of the last page of the SATIP.
DC Power
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MACO-QECP-009

Procedure Energizing Of Cables or Equipment The following items are considered to be mandatory inspection hold points for the Contractor before any cable or equipment is energized: a) Prior to energizing a cable it is essential to determine that this cable has been terminated to the correct locations per the approved installation drawings. b) The cable should be meggered to ensure insulation resistance integrity. c) Prior to energizing, grounding resistance tests should be conducted in accordance with the requirements of SAES-T-795. d) It will be mandatory that all personnel involved in the energizing of this cable are fully briefed as to the time which the event shall occur. It will be the responsibility of the senior technician to ensure that all personnel are a safe distance away during the energizing of these cable at all possible points of hazard for this cable. Disconnect Switch. Inspect the battery disconnect switch/circuit breaker to ensure that the cable terminals are adequate for the size power cable being used, and that the size of the switch enclosure provides sufficient room for proper cable bending radius. Stationary Batteries. The following items will be inspected in the battery room before, during, and after the installation of the batteries. a) Verify the battery rack is grounded at both ends with green and yellow grounding wire and that separate sections of the rack are bonded together. Ensure that safety rails have been provided. b) Ensure that the battery cables are properly color-coded. c) After all cable connections are completed verify that the battery terminals are greased and that battery straps are tightly connected. d) Ensure that cable lugs are properly sized. e) Ensure the battery cells are sequentially numbered. The positive cable to the rectifiers terminates in Cell #1 and the negative cable terminates in Cell #24.
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MACO-QECP-009

f) Verify that personnel protective equipment is available and stored in a cabinet, and that required signs have been posted and battery information has been conveniently placed on the wall (SAES-P103). g) Verify that the shower is at least 3 meters away from the nearest battery cell (SAES-B-069) or that a protective screen has been provided. If eyewash only (no shower) the separation shall be minimum of 1.5 meters. Rectifiers and Power Boards. The following inspections apply for the installation of the rectifiers/power boards: a) Ensure that the rectifiers are insulated from the cable trays and from the power distribution board. b) Ensure that the equipment racks are securely fastened to the floor and are also fastened at the top to the nearest overhead structure. Verify that the equipment racks are bonded to the overhead cable trays and grounded to the master ground bus (MGB). c) Ensure that a plexiglass cover is provided in the back of the power board. MCC/Partial MCC Upon completion of the Final Company inspections, a partial Mechanical Completion Certificate (MCC) (Form A-7213) can be issued and signed. The partial MCC shall not be signed if the Work is not completed as required by the project requirements. However, as determined by the designated MCC Committee Chairman, the MCC can be signed with an Exception Item List (EIL) attached if these exceptions do not prevent energizing the equipment and do not affect the safety and integrity of the project. Partial MCCS can be generated and signed/approved for each project subsystem. Upon Completion of the project these partial MCCs can be incorporated into the Final Project MCC. This method will expedite the installation activities. It is to the benefit of both the Contractor and the Company to utilize this method if possible for MCC approval.
DC Power
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MACO-QECP-009

Review, Witness And Hold Points The level of surveillance inspection for each activity is indicated in the SATIP column marked Surveillance/Inspection Code. The following codes are indicated: A1 W1 W2 H R1 R2 100% Actual Inspection / Test 100% Witness Inspection / Test Sample Witness Inspection / Test Mandatory Hold Point 100% Review Documents Sample Review Documents
Hold Point Work will be held until the inspection or test has been satisfactorily completed. Witness Inspection will be witnessed by inspection QC staff. Review QC staff will monitor the activity or review the verifying document records. 6 Documentation None
DC Power
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MACO-QECP-009

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF JUNCTION BOXES AND DEVICES

Index 1 2 3 4 5 6 Scope References Materials Control Quality Control Procedure Documentation Page 2 2 2 2 3 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Installation of Junction Boxes and Devices
Page 1 of 3
MACO-QECP-010

INSTALLATION OF JUNCTION BOXES AND DEVICES
SCOPE This procedure covers the inspection, method and criteria for installation of junction boxes and devices.
REFERENCE STANDARDS AND CODES
SAES-P-100 SAES-P-104 SAES-B-068 NEC NEMA 3 MATERIALS CONTROL
Basic Power System Design Criteria Wiring Methods and Materials Electrical Area Classification. National Electric Code National Electrical Manufacturers Association
a) Ensure that materials are handled in accordance with General Electric Procedure and Materials control System. b) Check all the materials received are in conformance with Purchase order and Specs. Requirements c) Check all materials are free from mechanical damage .Any damage or discrepancies shall be recorded and reported immediately to Materials dept. d) Store the materials in a safe place, free from dust and not exposed to sunlight. 4 QUALITY CONTROL a) Check junction boxes for sizes and types in conformance with Specification & drawings b) Where junction boxes are to be installed in hazardous areas, particular attention will be paid to their certification to ensure they are suitable in the classified areas. c) Support brackets, posts and stanchions will be checked against the detailed drawing and located in accordance with the layout drawings. d) Where industrial or vapor proof fittings are specified, their IP rating will be checked for suitability. e) Accessibility for the maintenance will be checked and it will be ensured that junction boxes do not conflict with other services or equipment
Page 2 of 3
MACO-QECP-010

f) Upon installation the supports will be checked to ensure rigidity and junction box fitting points are available. 5 CONSTRUCTION PROCEDURES a) Junction boxes shall be installed in accordance with the detailed drawings. All accessories and conduit fittings are installed where applicable and are of approved type materials. The Civil Erection Group will install concrete foundation .Prior to installing the supports, the fixing points and bases will be checked to ensure their line and level is correct .Cable entries will be checked to ensure they are clear of debris. All junction boxes supports shall be applied with prime coating and approved corrosive resistant epoxy paint finished prior to installation of boxes. All junction boxes and steel supports shall be provided with earthing wire securely and effectively bonded to main grounding grid.\ Ensure that proper conduit fittings are installed with threads fully engaged and the proper sealing compound is used .Sealing fittings and drains are installed as per detailed drawings. Plug or cap all unused threaded hubs opening with a metallic square head plug.
b)
c)
d) e)
f)
DOCUMENTATION None
Page 3 of 3
MACO-QECP-010

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF CABLE TRAYS

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Installation of Cable Trays
Page 1 of 3
MACO-QECP-011

INSTALLATION OF CABLE TRAYS 1 SCOPE This procedure covers the inspection, method and criteria for installation of cable trays, fittings and supports carried out by the Electrical Department. 2 REFERENCE STANDARDS AND CODES
a) b) c) d) e)
SAES-P-100 SAES-P-104 SAES-B-068 NEC NEMA
- Basic Power System Design Criteria - Wiring Methods and Materials - Electrical Area Classification. - National Electric Code - National Electrical Manufacturers Association
3 MATERIALS CONTROL Ensure that materials are handled in accordance with General Electric Procedure and Materials control System. Check all the materials received are in conformance with Purchase order and Specs. Requirements Check all materials are free from mechanical damage .Any damage or discrepancies shall be recorded and reported immediately to Materials dept. Store the materials in a safe place, free from dust and not exposed to sunlight. Cable trays to conform to SAES-P-104 Para 4.4 4 QUALITY CONTROL
CHECK FOR THE FOLLOWING Conformance to specification and drawings. All braces and supports are adequate to handle weight of cable trays and cables in accordance with detailed drawings. Hold down clips properly installed .Tray is included only on location shown on drawings. Expansion joints properly installed. No sharp edges to cut cables. No obstruction to pulling of cable. All covers, fire stops and partitioned installed. All earthing bonding jumpers are effectively grounded as per SAES-P-11. Check correct use off fittings and accessories for change indirection splices and drops. Spacing and clearances from other cables/wires with different system voltage levels. Cable tray is mechanically connected to conduit or raceways they terminate to.
Installation of Cable Trays Page 2 of 3 MACO-QECP-011

Check that installation of cable trays does not conflict to other services on equipment. 5 CONSTRUCTION PROCEDURES a) Cable trays shall be copper free aluminum, ladder type. b) Cable tray installation shall utilize ventilated, louvered cable tray covers secure with aluminum cover connector, with a 1220mm (4ft) min interval .The covers barriers and fittings should be constructed of the same material as the tray. c) Cable tray barriers should be solid, continous and non-combustible. d) Fabrication of steel structures bracket supports shall be in accordance with detailed drawings. e) The installed supports shall be inspected to ensure it is level and aligned vertical and whole assembly is rigid. f) Where supports are to be welded to structural steel, this shall be done prior to the application of paint or protective coatings. g) Where supports are bolted to structural steel, this shall be checked to ensure all bolts; nuts etc are correctly installed and securely fixed. h) Earthing bonding jumpers are properly connected and bonded to main ground grid. 6 DOCUMENTATION Field Installation Checklist Cable Tray
Installation of Cable Trays
Page 3 of 3
MACO-QECP-011

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF COMMUNICATION SYSTEMS

Index 1 2 3 4 5 6 Scope References Material Control Quality Control Testing Documentation Page 2 2 2 3 4 4
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Communication Systems
Page 1 of 4
MACO-QECP-012

INSTALLATION OF COMMUNICATION SYSTEMS 1 SCOPE
a) This procedure covers the inspection and test procedure pertaining to the installation f communication system in industrial and process areas. The equipment covered herein includes telephone and paging system. b) This procedure shall be applied to the inspection method and criteria for the installation work carried out by the electrical department.
REFERENCE STANDARDS The communication system design, installation and testing shall be in accordance with applicable section of the latest revision of the codes, standard and regulation of the organization below and Royal Commission for Jubail & Yanbu standards.
a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s)
ANSI NFPA NEC API NEMA IEEE NETA UL FM BICSI SAES-T-243SAES-T-435 SAES-T-481 SAES-T-622 SAES-T-629 SAES-T-632 SAES-T-633 SAES-T-903 SAES-T-916
AMERICAN NATIONAL STANDARDS INSTITUTE NATIONAL FIRE PROTECTION CODE National Electrical Code American Petroleum Code National electrical manufacturing association Institute of electrical & electronics engineer National electrical testing association Underwriters laboratory Factory mutual corporation Building industry consulting services intl Distribution &protection equipment Communication station protection Powered in-plant communication Communication conduct & manhole Telecom buried cable &wire Communication cable splicing Communication splice closure Communication electrical protection Communication building cable
Page 2 of 4
MACO-QECP-012

MATERIAL CONTROL
a) Check / inspect all the material received are in conformance with purchase order and relevant specification requirement ensure that all the material are handle in accordance with material control system. b) Check that telecom equipment & other related associated accessories are free from mechanical damages. Any discrepancies or parts found defective shall be recorded & reported immediately to MACO Material Control Department. c) Store all telecom equipments and other accessories in dust free area and protect them against atmospheric action and dirt. Most preferably to air- conditioned room to prevent damages of electronic parts. 4 QUALITY CONTROL
EQUIPMENT INSPECTION a) Prior to removal to site, the equipment will be identified and checked against the data sheets. Where equipment is to be installed in hazardous areas, particular attention will be paid to their certification to ensure they are suitable for the installation in the classified area. b) Equipment such as telephone / intercom handsets or radio pocket receiver which are supplied in section, or have accessories supplied loose, will be checked against the particular inventory. c) Unless otherwise stated, all tests shall be conducted by the site electrical QC inspector. EQUIPMENT INSTALLATION A) TELEPHONE & INTERCOM SYSTEMS 1. P.A.AB.X.S amplifier units, junction boxes and termination racks will be installed on prepared foundation and or other structural supports as per manufacturing recommendation. Prior to installation, the foundation base plates and floor fixing will be checked for location and level and the fixing points checked against their position on the respective panels. Cable sleeves and ducts will be inspected to ensure correct line and location. 2. Before installing in position, the equipment will be opened up and inspected for cleanliness to ensure no foreign bodies are present. 3. Installation will be witness to ensure the equipment is vertical and fixing bolts tightened. Where equipment consists of a number of panel sections, the assembly shall commence form the center section. Section on either side of the center shall be alternated, leveled and shimmed as necessary.
Communication Systems Page 3 of 4 MACO-QECP-012

4. The complete assembly will be checked t ensure alignment and level after tightening of the bolts. 5. Where equipment is to the wall mounted, the brackets will be checked against the detail drawing. Wall fixing will be checked to ensure they are secure prior to installation of the equipment. 6. Upon installation, the equipment will be inspected to ensure the fixing are secured properly. 7. The placement of telephone handsets will be checked against the layout dawning. 8. Conduits, cable trays and supports will be installed in accordance with approved drawings. 9. Cable and wires will be installed in accordance with approved drawings and Aramco standards. SEAS-T-916, SAES-T-243, SAES-T-435 B) PARTY PAGING SYSTEM. Paging system equipment such as amplifier, junction boxes, termination racks and speakers will be installed as per Royal Commission for Jubail & Yanbu standards. 2 The placement of handsets and speakers will be checked against the layout drawings. 3 Loudspeaker system will be inspected to ensure correct type and location, orientation and their fixing are secured properly. 4 Conduits, trays cables, and earthing system will be installed as in item (8) through (10) inclusive. TESTING 1
Communication system will normally be tested and commissioned by vendor representatives. a) Prior to energization, control panels will be merger tested to ensure it has Leakage paths to earth. Power and control circuits will be checked in accordance with manufacturing instruction. The test will b recorded. DOCUMENTATION Communication system test Inspection and test report.
b)
c) 6
Page 4 of 4
MACO-QECP-012

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF CONDUITS & FITTINGS

Index 1 2 3 4 5 Scope References Materials Control Quality Control Documentation Page 2 2 2 2 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Conduits and Fittings
Page 1 of 3
MACO-QECP-013

CONDUITS AND FITTINGS 1 SCOPE
These procedures covers the inspection and field installation checklist pertaining to the installation of above ground conduits and fittings carried out by the Electrical Department. 2 REFERENCE STANDARDS & CODES a) b) c) d) e) f) g) h) i) SAES-P-100 SAES-P-104 SAES-B-068 SAES-P-111 NEC NEMA NFPA UL SAMSS Basic Power System Design Criteria Wiring Methods and Materials Electrical Area Classification. Grounding System National Electric Code National Electrical Manufacturers Association National Fire Protection Association Underwriters Laboratories Saudi Aramco Material Supply Standard
MATERIALS CONTROL a) b) c) d) Ensure that materials are handled in accordance with Sec.III.5.1 (General Electric Procedure) and Sec.III.8.1 (Materials control System). Check all the materials received are in conformance with Purchase order and Specs. Requirements Where conduits and miscellaneous fittings are supplied loose, these shall be identified and checked against the equipment delivery. Ensure that conduits and fittings are stored and protected against atmospheric action, dust and dirt.
QUALITY CONTROL 4.1 CHECK FOR THE FOLLOWING a) b) Conduits and fittings to conform to SAES-P-104 Para 4.3. PVC coated 40 mils thick rigid steel conduit shall be used in damp locations, exposed to weather, direct buried underground and as conditions of installation, operations and on maintenance requiring protection from liquids, vapors or solids. Rigid steel ,galvanized conduit shall be used in wet locations, exposed to weather, in areas subject to mechanical injury defined as less than
c)

d)
e)
f)
g)
2.3 in above finished floor and accessible to authorized operating or maintenance personnel only Rigid Plastic conduit (PVC) shall be used below slabs on grade ,encased in concrete ,unless otherwise indicated in approved drawings .Riser elbows and extensions above grade or concrete shall terminate in rigid steel conduit ,using appropriate PVC to steel adapter Space conduit at least 6(150mm) from coverings of hot water pipes ,18(460mm) from covering on flues and breaching ,24 (600mm)from radiant heaters. Exposed conduits shall run parallel at or right angles with the lines of the buildings .Route exposed conduit to preserve head room, access space and work space. All wiring and cables installed in conduits will not exceed 40% conductor fill .Conductor fill of seal fittings shall not exceed 25%.
DOCUMENTATION Field Inspection Checklist.
Page 3 of 3
MACO-QECP-013

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF DISCONNECT SWITCHES

Index 1 2 3 4 5 6 Scope References Materials Control Quality Control Procedure Documentation Page 2 2 2 2 3 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Disconnect Switches
Page 1 of 3
MACO-QECP-014

INSTALLATION OF DISCONNECTING SWITCHES 1 SCOPE a) This procedure covers the inspection and test procedure pertaining to the installation of disconnecting switches. This procedure shall be applied to the inspection, method and criteria for installation work carried out by the Electrical Department.
b)
REFERENCE STANDARDS AND CODES a) b) c) d) e) f) g) h) SAES-P-116 16-SAMNS-510 NFPA-70. OSHA NEC NEMA IEEE SAMSS
Occupational Safety & Health Act. National Electric Code National Electrical Manufacturers Association Institute of Electrical & Electronics Engineers Saudi Aramco Materials Systems Specification.
MATERIALS CONTROL a) Ensure that materials are handled in accordance with Royal Commission for Jubail & Yanbu Procedure and Materials control System. b) Check all the materials received are in conformance with Purchase order and Specs. Requirements c) Check all materials are free from damage .Any damage or discrepancies shall be recorded and reported immediately to Materials dept. d) Store the materials in a safe place, free from dust and dirt.
QUALITY CONTROL a) Switches shall be furnished in NEMA Type 1 general purpose enclosure and/or NEMA Type 4 stainless steel watertight for outdoor use and wet locations. b) Covers for general purpose enclosure shall be of the hinged type provisions for pad locking covers in the closed positions with defeatable interlocks to prevent the cover from opening when the operating manhole is in the ON positions shall be provided. c) Enclosures shall be fabricated of code gauge steel, with a rust inhibiting primer and finished on baked enamel. Factory installed ground lugs shall be provided in each enclosure
Disconnect Switches
Page 2 of 3
MACO-QECP-014

d) All switches shall have switchblades, which are fully visible in the off position when the cover is open. Removable arc suppressor shall furnish where necessary to permit access to line-side hinges. Hinges shall be front removable; all heavy duty switches shall have live terminal shields. e) Switch mechanism shall be at the quick make, quick back type, with pad lockable operating handle as an integral part of the enclosure base. Switches shall have dual cover .Inter locks to prevent unauthorized opening of the switch when handle is on the ON position or closing of mechanical with covers in the open position. 5 INSTALLATION PROCEDURE a) Mount are individually enclosed disconnects rigidly ,and align properly on the building structure 1(25mm) off the wall and foot 10(1.8m) above finish floor. Use steel supporting frames as necessary or as shown in drawings. b) Provide and install a nameplate shall be engraved in bopt. Arabic & English indicating the name of the equipment served with circuit or motor number. c) Nameplate shall be black or white, laminated phenolic, engraved in min. (6.5mm) high lettering .Provide other or additional information on nameplates as required .Refer to each specification Sec.16lgt, for complete requirement for Id plates. d) Install nameplates to disconnect with appropriate sheet metal screws 6MF on types and pop-rivet are not acceptable 6 DOCUMENTATION Disconnect Switch Inspection Checklist
Disconnect Switches
Page 3 of 3
MACO-QECP-014

DOCUMENT TITLE:
PROCEDURE FOR: LOW VOLTAGE MOTOR CONTROL CENTER

Index 1 2 3 4 5 6 7 Page Purpose Scope References Materials Procedure Inspection & Testing Documentation 2 2 2 2 2 6 7
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Low Voltage Motor Control Center
Page 1 of 8
MACO-QECP-015

LOW VOLTAGE MOTOR CONTROL CENTER

1 Purpose: The purpose of this document is to define and establish systematic method or process to low voltage motor control centers or replace circuit breakers and motor starter controllers in existing motor control centers, in industrial and non-industrial facilities. 2 Scope: This document covers installation of low voltage motor control centers and replace or furnish circuit breakers and motor starter controllers inside motor control center. 3 References:
Codes and Standards: Comply with all applicable codes and standards including, but not limited to, those listed below: NEC (National Electrical Code) Royal Commission for Jubail & Yanbu Material Systems specifications ( SMSS ) Royal Commission for Jubail & Yanbu Engineering Standards (SES) SES - P 119-02 37 SMSS 32 SMSS Basic Design Aspects Circuit Breakers Metal Clad Switch Gear
Material: 4.1 General Requirements: 4.1.1 Motor Control Center Low voltage control gear or motor control centers shall comply with the following mandatory requirements. 4.1.1.1 4.1.1.2 Suitable for continuous operation. Ambient temperature shall be maximum of 40 deg c and minimum of zero deg c.

4.1.1.3 4.1.1.4 4.1.1.5 4.1.1.6 4.1.1.7 4.1.1.8 4.1.1.9 4.1.1.10
4.1.1.11 4.1.1.12
4.1.1.13 4.1.1.14
4.1.1.15
4.1.1.16
4.1.1.17
4.1.1.18
Rated current shall be 600 Amps ( minimum ) for horizontal bus & 300 Amps for vertical bus. Short circuit interrupting rating (minimum) shall be 25 KA rms. Rated operational voltage 480 volts & rated max. 575 volts or 600 volts. Rated short circuit with stand current shall be 25 KA RMS for 3 cycles. Die-electric test shall be 2.5 KV for one minute. All components and switching devices requiring routine maintenance shall be accessible. Roof lifting attachment shall be provided for lifting the entire shipping. Motor control centers shall be provided with a minimum of one spare and one space for every three vertical section. Openings between the vertical wire ways and switching assemblies shall be covered with removable non metallic barriers. The vertical section shall share a common main circuit horizontal bus and a common ground bus. All switching assemblies shall be with draw able type except circuit breaker greater than 225 Mmps shall be fixed. The switching assemble module can be removed without de energizing the MCC main circuit or without accessing the rear of the MCC. Exterior compartments shall be hinged type. But it is accepted that the horizontal wire way compartment shall not be hinged. In an MCC, under the test condition is shall not be possible for a flexible rod of 13 mm diameter with a rounded tip to contact live parts or being inserted into any openings. Any voltage greater than 24 volts is live parts& "opening" means the opening between separate compartments. All wire ways shall be accessible from the front of each vertical section via compartment doors. Horizontal wire ways shall have a minimum internal height of 150 mm. Each vertical section shall have a vertical wire way. This wire way shall inter connect the top and bottom horizontal wire ways. Power and control terminal blocks directly related to the switching assemblies may be installed with in the vertical wire ways adjacent to the switching assembly. MCC supplied in back to back configuration shall have two separate assemblies' utilizing independent main circuits.
Page 3 of 8
MACO-QECP-015

4.1.1.19
4.1.1.20 4.1.1.21 4.1.1.22
4.1.1.23 4.1.1.24 4.1.1.25
4.1.1.26
4.1.1.27
4.1.1.28
4.1.1.29
4.1.1.30
4.1.1.31 4.1.1.32
4.1.1.33 4.1.1.34
The main circuit horizontal bus system and ground bus system serving multiple vertical sections shall each have the same ampere rating. The horizontal bus, vertical bus and ground bus shall be rigid surface shall be silver or tin plated. All main circuit switches and main circuit breakers installed in MCC shall have the following characteristics. The exterior door shall be manually operable only with the door in the closed position. Operating handle shall be directly mechanically connected to the switch / breaker irrespective of the position in open position. The operating lock shall be pad lockable in the open position. There shall be external indication to show the handle position in open position. When the breaker is in the open position, the only voltage present in switching terminal shall be at the incoming terminal. MCC shall not have more than one disconnector. If a circuit breaker is used for disconnerctor. It shall not be equipped with instantaneous ground fault protection. Circuit breaker within switching assemblies shall be molded case construction. Circuit breaker within switching assemblies shall have a short circuit rating not less than that of the complete MCC. The main circuit contactors shall have electrically operated type, magnetically held & field replaceable coil. Mechanical interlocks shall be provided to prevent the compartment door, while the circuit breaker operating handle is in closed poison. Switching assemblies, controlling motors shall be factory wired to accommodate installation of a field start / stop device. Only electromechanical switching devices are permitted with in the hard wired circuit. Fuses shall not be used in the main circuit of an MCC with the following exceptions, if it is used to provide current limiting function as part of circuit breaker. Fuses shall be non renewable type. Fuse body shall not be of glass and rated a minimum of 240 V. If the switching assembly is feeding a motor, all motors shall have overload and instantaneous over current. Combination of thermal & magnetic breaker is acceptable. An overload of any of the three phase conductors shall open the main circuit to the motor. Trip characteristics shall be automatically ambient compensated. It shall be adjustable over a range of 90 to 110
Page 4 of 8
MACO-QECP-015

4.1.1.35
4.1.1.36
4.1.1.37
percent with the switching assembly compartment door closed. The switching assemblies shall be provided with individual control transformer will supply all control powers except space heater supply. At least one space heater shall be provided within each vertical section and shall be designed to eliminate internal condensation. Space heater shall be accessible, designed to operate continuously and the power supply shall be fed from an external source. All name plates tag, catalog designation and warning name plate shall be provided with the unit.
4.1.2
Feeder Circuit Breaker
Circuit breaker having a frame size of 150 amperes or less shall be molded case type with thermal magnetic non- inter changeable, trip free sealed trip units. Breaker contactor material shall be non welding type silver alloy. Breakers shall have arc- extinguishing chutes. 4.1.3 Starter Units 4.1.3.1 Unless and otherwise stated use combination starter, consisting of circuit breaker, fusible switch or motor circuit protector and magnetic starter. 4.1.3.2 Interrupting rating or circuit breaker shall be coordinated with main bus rating. Coordinate momentary short circuit of starter units with buses and circuit breakers. Use NEMA size 1 minimum starter capacity. 4.1.3.3 Magnetic starters shall have auxiliary contacts including one spare N.O and N.C contacts. 4.1.3.4 Provide local control devices, such as start/stop push buttons hand- off auto switch, indicating lights, control relays and timers as per the requirement. All starters shall have "red" indicating light for running and "green" for stop. 4.1.3.5 A minimum of 50 VA control transformer with primary and secondary fusses are required. 4.1.4 Control Devices Control relay shall be heavy duty industrial type and time delay shall be adjustable with spare N.O & N.C contacts. Push buttons shall be heavy duty and oil tight rated minimum 10 amperes continuous.
Page 5 of 8
MACO-QECP-015

4.2
Manufacturers Materials are selected purely on the basis of client's choice, subjected to compliance with project requirements. For new installation of motor control centers the product from the following manufacturers are used, if the client is not specific about any particular manufacturer. For the installation of breakers or starters selection shall be preferably of the same manufacturers of the existing motor control centers. 4.2.1 General Electric Co. 4.2.2 Cutler Hammer 4.2.3 Square D 4.2.4 Siemens 4.2.5 WESCOSA 4.2.6 JEDAC 4.2.7 And other approved manufacturers
Procedure: 5.1 Motor Control Centers 5.1.1 Install MCC in accordance with manufacturer's instructions. 5.1.2 Verify all loads on the MCC including the loads of equipments and devices to be connected. Also verify that cables and conduits are size for equipment's loads in accordance with NEC or equivalent standards. 5.1.3 When the main systems of equipments are directly connected together, the entire bus system shall have the same rating. 5.1.4 If an MCC is fed from a feeder breaker within a switch gear the switch gear and MCC assembly shall not be physically connected together. 5.1.5 Keep 1.5 meters in front from the MCC back to back configuration has two fronts and hence, 1.5 meters on both fronts shall be kept. 5.1.6 When an MCC is installed in front of a switch gear or another MCC, the space between the two shall be 2 meters. 5.1.7 Never use cable to extend the main bus of an MCC. 5.1.8 Lifting/handling devices shall be provided for any with-draw type component weighing over 20 kg. 5.1.9 Panel boards and dry type distribution or lighting transformers shall not be installed with in an MCC. 5.1.10 Where low voltage MCC is fed from a source with fuse protection (over head power line), see that all motors be equipped with single-phasing protection.
Page 6 of 8
MACO-QECP-015

5.1.11 No devices (circuit breaker, terminal blocks, relays etc.) shall be field installed within the wire ways of MCC. 5.1.12 Barriers shall be placed in all services-entrance of motor control centers to isolate service bus bars and terminals from the remainder of MCC. 5.1.13 The ampere rating or setting of all over current protective devices shall not exceed the rating of the common power bus. 5.1.14 If the MCC is within the same electrical room as the switch gear from which it is fed, no main disconnector shall be installed with in the MCC. 5.1.15 If the MCC is not within the same electrical room as the switch gear from which it is fed, and if local isolation is required a switch shall be specified as the main disconnector inside MCC. 5.1.16 No intermediate circuit breaker shall be installed between the switch gear and the MCC. 5.2 Installations of Circuit Breaker/Starters Inside MCC 5.2.1 Set motor circuit protectors and circuit breaker based on the connected load. 5.2.2 Check and provide thermal over load on each phase of a unit to match overload to motor full load current. 5.2.3 Install conduits, wires/cables and grounding interconnections as per NEC and other standards. 5.2.4 Verify the name plate and other identifications for accuracy and compliance and requirements. 6 INSPECTION & TESTING 6.1 Inspections and testing shall be performed in accordance with the code and client specifications. 7 7.1 Associated Documentation Low Voltage Motor Control Centers Checklist (QECP-007-01-MC)
Page 7 of 8
MACO-QECP-015

LOW VOLTAGE MOTOR CONTROL CENTER INSTALLATION CHECKLIST
QECP-007-01-MC CONTRACT: LOCATION: CABLE NO: DRAWING NO.: _____________________ _____________________ _____________________ _____________________ REFERENCE: PROJECT: SYSTEM: AMB. TEMP. _________________ _________________ _________________ _________________
SI. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
INSPECTION POINTS
Check MCC for any damage during shipping. Open and Check all compartments to verify size& type breakers provided as per requirements. Starters, overload protection settings as per project's requirements. Physical check on power circuit wires, control wiring connotations. Race ways fitting given as per top feed or bottom feed of MCC. Check all indicating lights (start, stop and trip ) are working. Check the draw-out tray bus bar spacing, isolation barrier and locking mechanism are as per standard. Foundation and mounting, in such a way that no water get into MCC. Space between the wall, space between the other units & back to back mounting space as per standard. Grounding as per standard. No instrument installed in vertical and horizontal wire ways. Out going wires terminations tight properly and pulled through the vertical and horizontal wire ways. Bushings are provided for all conduit entry. Check the space heater in working condition and out side power given Labels, tags etc. are as per the requirement and as per the specification.
ACCEPT
REJECT
N/A
Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

Page 8 of 8
MACO-QECP-015

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF DRY-TYPE TRANSFORMERS

Index 1 2 3 4 5 6 Scope References Materials Quality Control Construction Procedures Documentation Page 2 2 2 3 3 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Dry-Type Transformers
Page 1 of 3
MACO-QECP-016

INSTALLATION OF DRY-TYPE TRANSFORMERS

1 SCOPE a) b) This procedure covers the inspection and test procedure pertaining to the installation of dry type transformers This procedure shall be applied to the inspection, method and criteria for installation work carried out by the Electrical Department.
REFERENCE STANDARDS AND CODES NEC NEMA UL SAES-P-100 SAES-P-114 SAES-P-121 SAES-P-111 ANSI National Electric Code National Electrical Manufacturers Association Underwriters Laboratories. Basic Power System Design Criteria System & Equipment Protection Transformers. Grounding System. American National Standards Institute
MATERIALS CONTROL 3.1 EQUIPMENT INSPECTION a) Upon receipt at the storage and handling area, the transformer shall be inspected for mechanical damage; any damage or discrepancies will be recorded and reported immediately to MACO. b) The nameplate will be checked against the transformer specifications data sheet in conformance with purchase order. c) Where transformer auxiliaries are shipped loose, these shall be identified and checked against the equipment delivery. d) Store the transformer on dust free area and protect them against atmosphere action and dirt. e) Ensure those transformers are handled in accordance with this Section 3, Materials Control System. f) Check that enclosure is suitable for the location where unit will be installed.
Page 2 of 3
MACO-QECP-016

QUALITY CONTROL CHECK FOR THE FOLLOWING: a) b) c) d) e) The transformer nameplate data will be checked against technical specification to ensure its conformity. The transformer concrete foundation will be checked for cleanliness and proper level. Check the location and alignment of cable ducts to ensure sufficient clearance for entry and glanding of cables. The winding insulation resistance will be megger tested and recorded. Check the feeder cable sizes and type in conformance with the design and specification. Ensure continuity and megger tests have been done prior to termination. Check earthing connection is potentially bonded to main grounding grid.
f)
CONSTRUCTION PROCEDURE a) b) c) d) e) Construct concrete foundation and other structures in accordance with approved design drawings and Proponent Standard. Install transformer in position and ensure cable duct is in their correct location and cables are properly oriented. The transformer will be inspected for mechanical damage and shall be securely fastened with bolts, nuts and washers. Prior to connection of power and control cables, check will be carried out on the transformer windings and protective devices. The winding insulation resistance will be Megger tested in accordance with Aramco Test procedure 7825 as follows: 1. 480V Transformer Megger at 1000 V 2. 4.16V Transformer- Megger at 5000V 3. 13.8V Transformer Megger at 5000V The test will be conducted between primary and secondary windings to earth and between the two windings. All tests will be conducted by Site Electrical Supervisor witnessed and recorded by the Site Electrical QC Inspector. Connect all earthing connection and bond all metal structures to main ground grid.
f)
DOCUMENTATION a) Form QECP-016-01-DT b) Form QECP-016-02-DT Dry Type Transformer Inspection record. Test records.
Page 3 of 3
MACO-QECP-016

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF OIL-FILLED TYPE DISTRIBUTION TRANSFORMERS

Index 1 2 3 4 5 Scope References Materials Quality Control Documentation Page 2 2 2 3 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Oil-Filled Type Distribution Transformers
Page 1 of 4
MACO-QECP-017

INSTALLATION OF OIL-FILLED TYPE DISTRIBUTION TRANSFORMERS

1 SCOPE a) b) This procedure covers the inspection and test procedure pertaining to the installation of Power Transformer. This procedure shall be applied to the inspection, method and criteria for installation work carried out by the Electrical Department.
REFERENCE STANDARDS AND CODES NECA NETA SAES-Q-Series SAES-T-Series NEC NEMA UL SAES-P-100 SAES-P-104 SAES-P-119 SAES-P-111 ANSI API IEEE FM National Electrical Contractors Association Standard of Installation National Electrical Testing Association Concrete Construction Communication National Electric Code National Electrical Manufacturers Association Underwriters Laboratories Basic Design Criteria Wiring Methods & Materials Substation. Grounding System. American National Standards Institute American Petroleum Institute Institute of Electrical & Electronics Engineers. Factory Manual Corporation.
MATERIALS CONTROL EQUIPMENT INSPECTION a) Upon receipt at the storage and handling area, the transformer shall be inspected for mechanical damage; any damage or discrepancies will be recorded and reported immediately to MACO Materials Department The nameplate will be checked against the transformer specifications data sheet in conformance with purchase order. Where transformer auxiliaries are shipped loose, these shall be identified and checked against the equipment delivery.
b) c)
Page 2 of 4
MACO-QECP-017

d) e) f) g) h)
Store the transformer on dust free area and protect them against atmosphere action and dirt. Ensure those transformers are handled in accordance with this Section 3, Materials Control System. Check that enclosure is suitable for the location where unit will be installed. Where oil immerses transformer is delivered oil-filled, the oil level will be checked to ensure no leakage. Where an oil conservator with end breather is installed, the silica gel in the breather will be checked to ensure no ingress of moisture is present.
QUALITY CONTROL INSTALLATION AND TEST a) b) c) d) The mechanical erection group in accordance with their quality control procedure will carry out the transformer installation. Prior to installation ,the transformer foundations will be checked for cleanliness and proper elevation as per approved design drawing Check the location and alignment of cable ducts to ensure sufficient clearance for entry and glanding of cables The installation of the transformer will be witnessed by the Site Electrical QC Inspector to ensure correct orientation and alignment of bus duct and or cables. The transformer will be inspected for mechanical damage and shall be securely fastened with bolts, nuts and washers. Connect all earthing connections and bond all metal structures to main ground grid. Prior to connection of the power & control cables or bus ducts checks will be carried out on the transformer windings and protective devices. The winding resistance will be megger tested in accordance with Aramco Test Procedure 7825 as follows: 1. 480V Transformer -Megger 1000V 2. 4.16V Transformer -Megger 5000V 3. 13.8V Transformer -Megger 5000V The test will be conducted between the primary and secondary windings to earth and between the two windings. All tests shall be conducted by the Site Electrical Supervisor witnessed and recorded by the Site Electrical QC Inspector. For transformer above 500KVA ,voltage ratio be checked by voltage injection test and recorded
e) f)
g)
h)
Page 3 of 4
MACO-QECP-017

TRANSFORMER OIL a) Transformer insulating oil will be tested using fosters type OTS 60(Auto) or equivalent dielectric test set. Where the transformer has been supplied pre-filled with oil, sample shall be taken from the lowest possible point in the tank. Where the insulating oil is supplied separately, samples shall be taken from the containers prior to filling. b) The test shall be carried out in accordance with Aramco test procedure 7825 .The oil shall be tested to ASTM D877 and Aramco Standard and SAES-P-120. The test parameter is shown on Table -013. c) The test will be conducted by the Site Electrical Supervisor witnessed and recorded by the Site Electrical QC Inspector d) After oil filling is complete, the final level and pressure surge devices will also be checked for completeness. Valves on air lines to radiators, conservators, air dryers, insulating bushes and flanges will be checked. The whole system will be inspected to ensure no oil leakages and reported. PROTECTION AND CONTROL DEVICES a) Transformer off-load charger will be inspected for freedom of movement and locked off at the position specified on the equipment data sheet. b) Direct mounted indicating gauges shall be inspected for correct operation. c) Trip settings of level, temperature and surge pressure devices will be checked. d) The results of tests will be recorded. (Final Inspection Record)
DOCUMENTATION a) Form QECP-017-01-OT b) Form QECP-017-02-0T c) Form QECP-017-03-OT Oil Filled Inspection Record. Power Transformer Test Record. Pre-commissioning Form-Test Inspection Records
Page 4 of 4
MACO-QECP-017

DOCUMENT TITLE:
PROCEDURE FOR: INSTALLATION OF BATTERIES AND CHARGERS

Index 1 2 3 4 5 Scope References Materials Quality Control Documentation Page 2 2 2 3 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Batteries and Chargers
Page 1 of 5
MACO-QECP-018

INSTALLATION OF BATTERIES AND CHARGERS

1 SCOPE a) This procedure covers the inspection and test procedure pertaining to installation of batteries and battery charger and uninterrupted power supply systems. This procedure shall be applied to the inspection, method and criteria for installation work carried out by the electrical department.
b)
REFERENCE STANDARDS SAES-0111 SAES-P-100 SAES-P-103 ADP-P-176 NEC ANSI NEMA UL Power Supplies Basic Design Criteria Batteries and UPS System Un-Interruptible Power Supply System National Electrical Code American Electrical Manufactures Association National Electrical Manufacturers Association Underwriters Laboratories
MATERIALS CONTROL 1.3.1 Equipment Inspection a) Upon receipt at the storage and handling area, the equipment will be inspected for mechanical damage. Any damage or discrepancies shall be recorded and reported immediately to MACO Material Department. b) Check Inspect all the materials received are in conformance with purchase order and specification requirement. Ensure that equipments are handled in accordance with Sec. 3 (Materials Control System).
Page 2 of 5
MACO-QECP-018

c) Particular attention will be paid to the condition of battery charging panels which have panel fascia mounted instruments. Where these panels are sealed to prevent the ingress of moisture of dust, they shall not be disturbed unless damage is observed. d) Batteries will be removed from their packing cases and inspected for damage. Where batteries are received filled with electrolyte, the transport sealant will be removed to allow air circulation prior to storage. Where batteries are received dry, the sealant may be left in place. e) Batteries will be returned to their packing cases and stored at a dry, clean and preferably cool location according to manufacture instructions. f) Store the battery charger dust free area and protect them against atmospheric action and dirt. Preferably in air-conditioned room to prevent damages of electronics parts.
QUALITY CONTROL 4.1 Battery Installation a). Prior to installation, the battery room will be inspected to ensure the floor finish is complete, clean and free form debris and obstruction. Any floor wall fixings should be installed. b). Battery racks ventilation should be complete and functional according to the contract specification and where installed, eyewash systems will be functional. c) Battery racks will be inspected to ensure they are assembled according to manufacturer instruction and detailed drawings. They should also be stable and properly fixed. d) Battery placement will be checked to ensure the arrangement of the positive and negative terminals as per the connection diagram. The final connection will be checked to ensure tightness and the correct polarity has been followed. e) Where batteries are received empty, they will be filled with electrolyte. Before preparing the electrolyte, the supervisor will ensure the operations have the correct protective clothing and that a supply of water is available to wash away any spillage.
Page 3 of 5
MACO-QECP-018

After preparation, the specific gravity of the solution will be checked and adjusted to the correct value as per the manufacturer instructions. The filling process will be supervised to ensure the cells are filled to the correct level giving sufficient time for setting. f) Where batteries are received filled the electrolyte level will be checked and topped up as required. g) When filling is complete the complete arrangement will be checked to ensure it is clean and free from moisture. 4.2 Charger and Inverter Panel Installations
a) Base plate, floor fixings etc. will be checked for level and location and fixing points checked against their position on the respective panels. Cable sleeves and ducts will be inspected to ensure correct line and location. b) Before installing in position, sections will be opened up and inspected for cleanliness and ensure no foreign bodies are present. Dust will be removed using a vacuum cleaner or rags as appropriate. c) The panel section will be inspected for mechanical damage and megger checked to ensure that it has no direct connection to earth. d) Installation will be witnessed to ensure the equipment is vertical and fixing bolts tightened, where equipment consists of a number of panel section. Sections on either side of the center shall be alternated, leveled and shimmed as necessary. e) The complete assembly will be checked to ensure alignment and level after tightening of the bolts. 4.3 Inspection and Test
a) Control panels will be inspected to ensure three are no loose connections and the insulation resistance checked using a 500-volt megger to ensure that it has no direct connection to earth. b) The ratings and settings of fuses and protective devices will be checked against the panel schedule. c) The control panel will be energized and functionally checked in accordance with the manufacturer instructions.
Page 4 of 5
MACO-QECP-018

For D.C. battery chargers, the output voltage, float and equalizing charge setting will be checked. The operation of all panel indicators will be checked. Fault conditions will be simulated and the operation of all alarms and annunciators witnessed. Inverter system will be checked as above and the output voltage and frequency checked. The operation of the static changeover switch will be checked according to manufacture instructions. d) The test will be conducted by the site Electrical Supervisors witnessed and recorded by the Electrical QC Inspector. The results will be recorded for battery chargers and for inverse systems. 4.4 Battery Charging
a) Before charging, the battery cell plugs will be loosened and the electrolyte level rechecked. b) Connection to the charger will be checked to ensure the correct polarity. c) The room ventilation system will be checked to ensure it is fully operational. d) The battery system will be charged according to the manufacturer instructions. Reading will be taken throughout the charging period. Where a constant voltage rises will be recorded. Where a constant voltage is applied, the voltage and drop in charging current will be recorded. Throughout the charging period the battery temperature shall be checked and the average value recorded. Attention shall be paid to individual cells with higher average temperatures. 5 Documentation Battery Installation Inspection/Charger Report.
a) Form QECP-018-01-BT
Page 5 of 5
MACO-QECP-018

DOCUMENT TITLE:
PROCEDURE FOR: ELECTRICAL DUCT BANKS & MANHOLES

Index 1 2 3 4 5 6 Scope References Materials Quality Control Procedures Documentation Page 2 2 2 2 4 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Electrical Duct Banks and Manholes
Page 1 of 4
MACO-QECP-019

INSTALLATION OF ELECTRICAL DUCT BANKS AND MANHOLES

1 SCOPE a) This procedure covers the inspection and test procedure pertaining to the installation of underground utilities, duct bank, duct bank cables and conduits. b) This procedure shall be applied to the inspection ,method and criteria for installation work carried out by the Electrical Department. 2 REFERENCE STANDARDS AND CODES
SAES-P-100 SAES-P-104 SAES-B-068 NEC NEMA S.A.G.1.2.705 SAES-P-111 3 MATERIALS CONTROL
Basic Power System Design Criteria Wiring Methods and Materials Electrical Area Classification. National Electric Code National Electrical Manufacturers Association Splicing /Terminations. Grounding Systems
a) Ensure that materials are handled in accordance with Proponent Procedure and Materials control System. b) Check all the materials received are in conformance with Purchase order and Specs. Requirements. c) Check all materials are free from mechanical damage. Any damage or discrepancies shall be recorded and reported immediately to Materials Dept. d) Store the materials in a safe place, free from dust and not exposed to sunlight. 4 QUALITY CONTROL a) PVC coated 40 mils thick rigid steel jacketed conduit and fitting shall be used in damp locations, exposed to weather, direct buried under and in conditions of installations, operation, or maintenance protection from liquids, vapors or solids. b) Rigid steel, galvanized conduit shall be used in wet locations, exposed to weather, in areas subject to mechanical injury defined as less than 2.3 meters
Page 2 of 4
MACO-QECP-019

above finished level and accessible to authorized operating or maintenance personnel. c) Rigid plastic conduit (PVC) shall be used below slabs or grade, encased in concrete, unless otherwise indicated on approved construction drawings. Riser elbows and extensions above grade or concrete slabs shall terminate in rigid steel conduit, using appropriate slabs PVC to steel adapter. d) Plastic conduit (PVC) bends shall be factory made bends, or field bend using approved heat box bender and conduit mandrels to assure full inside diameter and prevent deforming or discolor conduit. All bends shall have a radius not less than the required by NEC-346-10. e) All underground work shall be in accordance with Section III.1.2 (Excavation and Backfill) Section III.1.4 (Trenching and Backfilling), SAESP-104 and Proponent Standard Drawings. f) Check that an excavation permit has been obtained prior to commencement of work on hazardous restrictive area. 1. Refer to SAES-T-928, Para 4.1.2.1 for information on processing and co-ordination with Non Proponent agencies. Otherwise, work permits shall be handled in accordance with G.I.No.2-100. 2. Extreme caution shall be exercised when excavating near the existing gas, oil and other hydrocarbon pipelines and power cables or conductors. No work shall start in the vicinity of these facilities until the proper work permits have been obtained and countersigned by the appropriate agencies including PDD (Power Distribution Department) where power cables or conduits are involved. g) Check that level, location, and depth of trenches are correct. h) Check that installation of materials does not conflict with other services or equipment. i) Check the preparation of cable or conduit trenches prior to installation. j) Check that the material is installed according to Manufacturers recommendations. k) The minimum depth of burial and restoration requirements for underground installation shall be as specified in SAES-P-104 and comply with Proponent Standard Drawings. l) All underground cable or conduit routes shall be marked with appropriate post cable markers at 30 m intervals, at every junction and at every change of direction as per Proponent Standard Drawings. m) Following installation of cables/conduits, prior to termination to electrical equipment, the cables shall be subject to an insulation resistance test. Low voltage (600V and below) cables, including cable splices and existing cables, shall be 500V DC megger tested after installation (prior to backfilling in the case of direct buried cables) and prior placing in service. Medium voltage cables (5KV and above) shall be tested as per SAES-P-104,Para 9.2. Record results for low voltage cables on approved forms and medium voltage cables on approved Proponent Form.
Page 3 of 4
MACO-QECP-019

CONSTRUCTION PROCEDURES 1. All excavation work shall proceed with care to avoid disturbing existing underground installations. Hand tools shall be employed exclusively for investigative digging to minimize disturbances. a) Cable/Conduit Laying: Before this is done, the bottom of the trench must have a sand cushion of at least 150mm (6) as per Proponent Standard Drawings and if cables/conduits or more are to be laid in the same trench they must comply with SAEP-P-104, Para II. Any cable/conduit passing or crossing through an existing pipeline or cable must be as per SAES-B-064. b) Covering of Cable/Conduit: Cover the cable with a dry sand to a height of at least 300mm (12), then put a red concrete tile of 50mm (2) thickness above as per Proponent Standard Drawings. c) Burying of Cable/Conduit: bedding and covering of sand shall be packed around the cable /conduit to prevent stone bruises and assist in heat dissipation. Minimum depth of direct buried cable/conduit from grade (surface) level to top of the cable/conduit shall be as per Proponent Standard Drawings. 2. Splicing of conductors shall be kept to a minimum. A maximum of 2 splices be permitted in any one circuit for new installations of cables rated above 1000V.Splices and terminations of cables rated above 1000V shall be made by personnel certified in accordance with Proponent G.I.2.705 3. Splicer certification cards shall be submitted to SAPIS for verification and issuance of the splicer job clearance card (Aramco 8233-22) prior to any splices of terminations being made on cables rated above 1000V. 4. All buried or concealed connections and splicers for the grounding system shall be inspected and approved by Proponent before concealment.
DOCUMENTATION Form QECP-019-01-DB Form QECP-019-02-DB Form QECP-019-03-DB Form QECP-019-04-DB Duct Manhole Field inspection Checklist /Electrical Manhole Underground Cable Duct Bank Test Under ground Electrical Conduit.
Page 4 of 4
MACO-QECP-019

DOCUMENT TITLE:
PROCEDURE FOR: INSIDE BUILDING PIPING AND FITTINGS
DOCUMENT NO.: MACO-QMCP-001

Index 1 2 3 4 5 6 Purpose Definitions Safety References Quality Procedures Documentation Page 2 2 2 2 3 5
001 ISSUE NO.
04/09/09 ISSUE DATE
MACO-QMCP-001 DESCRIPTION
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Inside Building Piping and Fittings
Page 1 of 5
MACO-QMCP-001

INSIDE BUILDING PIPING AND FITTINGS

This quality Procedure shall cover inspection works for Piping and Fitting works inside buildings. 1.0 PURPOSE This Quality Procedure has been developed in order to ensure the main work operations and performance of associated Quality Control activities during Piping and Fitting works inside buildings. 2.0 DEFINITIONS QMP QCP ITP Quality Management Procedure Quality Control Procedure Inspection and Test Plan
3.0
SAFETY 3.1 To ensure that work permit is valid, if applicable and all works done in safest possible manner consistent with good construction practices.
4.0 REFERENCES SAES A - 004 SAES L - 001 SAES L 005 SAES L 008 SAES L 009 SAES L - 032 SAES L 042 General Requirements for Pressure Testing. Piping Standards Piping Components Selection of Valves Metallic Flanges, Gaskets and Bolts for Low and Intermediate Temperature Service. Material Selection of Piping Systems Plant Utility Stations
Page 2 of 5
MACO-QMCP-001

SAES S 050
Sprinkler & Standpipe System Components in Buildings. Saudi Aramco Plumbing Code Installation of Utility Piping System Gate Valves Globe Valves Check Valves General Requirements for Valves Building Service Piping PVC Plastic Pipe Schedule 40 PVC Sewer Pipes and Fittings Disinfecting Water Mains Safety Identification and Color Coding Emergency Eye Washes and Showers Safety and Fire Water Storage, Handling and Installation of Pipe Externally Coated with FBE or Polyethylene General Specifications of applying Heat-Shrink Sleeves to Coated Pipes. Hand Applied Tape Wrapping of Buried Pipes.
SAES S 060 SAES S 070 04-SAMSS 001 04-SAMSS 002 04-SAMSS 005 04-SAMSS-035 ANSI B 31.9 ASTM D 3311 ASTM D 2729 AWWA C 651 SAES B 067 SAES B 069 SAES B Series SAES H 200
SAES H 204
SAES H 203
5.0
QUALITY PROCEDURES 5.1 Piping Works 5.1.1 Perform work in accordance with Proponent and referenced International Codes and standards.
Page 3 of 5
MACO-QMCP-001

5.1.2 5.1.3
5.1.4 5.1.5 5.1.6
5.1.7
5.1.8
5.1.9 5.1.10 5.1.11
5.1.12 5.1.13
Conform to SAES Codes for installation of backflow preventive devices. Below grade utility and drinking water piping shall be Type K copper tube hard drawn temper conforming to ASTM B-88 with wrought copper solder joint fittings compliant to ANSI B-16.22 (Solder using s/s tin antimony solder. Above grade utility and drinking water piping shall be Type L copper tube hard drawn temper. Dielectric unions shall be provided between dissimilar materials. All under slab sanitary sewer pipes from fixtures to the building main and up to 1.5 m from the building shall be PVC pipe Schedule 40. Fittings shall be PVC schedule 40. Solvent weld shall comply with ASTM D 2564 solvent cement. All overhead and furred in sanitary sewer pipes form fixtures up to the crisp of riser shall be acid-resisting oakum (appropriate rubber gaskets are also ok). Above and below grade acid-resistant pipe shall be schedule 40 polypropylene and joints shall be heat fusion bonded. PVC schedule 40 now acceptable for battery rooms (no solvents or hydrocarbon waste allowed). All roof drain and vent shall be galvanized steel, class 125. Downspout exterior to building shall be corrugated sheet metal or galvanized steel, class 125. All excavations shall be restored to its required level. The bottom of trench shall be dry prior to installation (Sand bedding / surround to be used). After installation, all pipe ends shall be capped to prevent egress of unsuitable materials. The trench bottom shall be continuous, smooth, free of rocks and in accordance to the line and grade shown in the drawing.
5.2 Installation 5.2.1 5.2.2 Remove foreign matter from inside of pipe before installation. Adequately support vertical lines at their bases or by a suitable hanger place in horizontal line near riser or by a base fitting set on pedestal. Run piping in straight lines and square with the building. Riser lines to be plumb. Provide dielectric fittings for connecting dissimilar metals. Do not route piping over any electrical equipment where the possibility of damage exists.
5.2.3
5.2.4
Page 4 of 5
MACO-QMCP-001

5.2.5
Provide flanges and unions throughout piping system to facilitate the installation and removal of piping and equipment. Provisions must be included for servicing and removal of equipment without dismantling piping works. Place storm drainage pipes, sanitary sewer pipes, waste pipes and drain pipes at elevation and slopes as per drawing. Do not install underground piping when bedding is wet. Cut pipe ends with pipe cutter only. Hacksaw cutting shall not be allowed.
5.2.6
5.2.7
5.2.8 5.2.9
5.2.10 Provide adapter where C.I. pipes connects PVC pipes. 5.2.11 Pecking, caulking and doping of pipes shall not be allowed.
6.0
DOCUMENTATION. Inspection and Test Plan Inspection and Test Record
Page 5 of 5
MACO-QMCP-001

DOCUMENT TITLE:
PROCEDURE FOR: PIPE SLEEVES

Index 1 2 3 4 5 6 7 Scope Purpose Definitions Safety References Quality Procedure Documentation Page 2 2 2 2 2 3 4
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Pipe Sleeves
Page 1 of 4
MACO-QMCP-002

PIPE SLEEVES
1 SCOPE 1.1 This covers procedures for inspection to be followed during installation of pipe sleeves including refrigerant pipes, water, drain and vent pipes passing through floor slabs, grade beams, walls and roofs. 1.2 This covers the inspection of all aspects of pipe sleeves passing through floor slabs, grade beams, walls and roofs. This procedure shall be used in conjunction with applicable manufacturers installation and maintenance instruction manuals.
1.3
PURPOSE a. To ensure that all items required by this Contract shall conform to Project specifications and construction drawings. This procedure shall ensure that the main inspection requirements are met and that the findings and corrective actions are followed. To achieve acceptable installation requirements and workmanship.
b.
c. 3
DEFINITIONS HVAC QCP ITP Heating, Ventilating and Air Conditioning. Quality Control Procedure Inspection and Test Plan
SAFETY 4.1 To ensure that Work permit is valid, if applicable and all works done in the safest possible manner consistent with good construction practices.
REFERENCES SAES-K-001 Heating, Ventilating and Air-Conditioning.
Pipe Sleeves
Page 2 of 4
MACO-QMCP-002

SAES-K-100 SAES-M-100 SAES-S-060 SAMSS
Saudi Aramco Mechanical Code (HVAC) Saudi Aramco Building Code Saudi Aramco Plumbing Code Saudi Aramco Material System Specifications
QUALITY PROCEDURE 6.1 General 6.1.1 All HVAC equipment to be supplied and installed shall have prior approval from Proponent. All equipment shall meet the project specifications and suitable for installation as required and in compliance with the manufacturers recommendations. 6.2 Quality Control 6.2.1 Deliver, store, protect and handle products as per manufacturers and Proponents requirements. 6.3 Installation
6.3.1 Provide block-outs for pipes passing through walls or slabs. Indicate correct size, locations and alignment of all sleeves. Provide schedule 40 galvanized steel sleeves through concrete or masonry. Provide sheet metal sleeves through fire rated gypsum walls (Plastic sleeves through non rated gypsum walls). 6.3.2 Size of pipe sleeves shall permit placing of pipe, insulation and specified sealing materials. Seal sleeves through fire walls with approved rated sealant. 6.3.3 Extend sleeves through floor 25 mm (1 inch) above finished floor level unless otherwise indicated or specified. Caulk Sleeves. 6.3.4 Extend wall and portion sleeves through and cut flush with each surface, unless otherwise indicated or specified. 6.3.5 Set sleeves in position in form works and provide reinforcements. 6.3.6 Size sleeves large enough to allow for movement due to expansion and contraction. Provide for continuous insulation wrapping.
Pipe Sleeves
Page 3 of 4
MACO-QMCP-002

6.3.7 Where piping or ductwork penetrates floor, ceiling or walls, close off space between pipe or duct and adjacent work with fire stopping insulation and caulk. Provide close fitting metal collar or escutcheon covers at both sides of penetration. 6.3.8 Install chrome plated steel escutcheon at finished surfaces. 6.3.9 After piping has been installed, seal the annular space between piping and sleeves with specified materials.
DOCUMENTATION 7.1 QMCP-002-01-ITP 7.2 QMCP-002-02-QR Inspection and Test Plan Quality Record.
Pipe Sleeves
Page 4 of 4
MACO-QMCP-002

DOCUMENT TITLE:
PROCEDURE FOR: ANCHORS, SUPPORTS AND THRUST BLOCKS

Index Page
1 2 3 4 5 6 7
Scope Purpose Definitions Safety References Quality Procedure Documentation
2 2 2 2 2 3 4
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Anchors, Supports and Thrust Blocks
Page 1 of 4
MACO-QMCP-003

ANCHORS, SUPPORTS AND THRUST BLOCKS
1.0
SCOPE 1.1 This covers procedures for inspection to be followed during Installation of supports, anchors and thrust blocks for HVAC system. 1.2 This covers the inspection of all aspects of supports, anchors and Thrust blocks for HVAC system including water and drainage pipes. 1.3 This covers the inspection of all aspects of supports, anchors and thrust blocks for HVAC system including water and drainage pipes.
2.0
PURPOSE 2.1 To ensure that all items required by this Contract shall conform to project specifications and construction drawings. 2.2 This procedure shall insure that the main inspection requirements are met and that findings and corrective actions are followed.
3.0
DEFINITIONS HVAC QCP ITP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
4.0
SAFETY 4.1 To ensure that Work Permit is valid, if applicable and all works done in the safest possible manner consistent with good construction practices.
5.0 REFERENCES SAES-K-001 SAES-K-100 Heating, Ventilating and Air-Conditioning Saudi Aramco Mechanical Code (HVAC)
Page 2 of 4
MACO-QMCP-003

SAES-S-070 SAES-S060 SAES-l-011 ASME-B-31.9 UMC Company
Installation of Utility Piping System Saudi Aramco Plumbing Code Flexibility, Support and Anchoring of Piping. Building Services Piping. Uniform Mechanical Code Proponent
6.0 QUALITY PROCEDURES 6.1 General 6.1.1 All HVAC equipment to be supplied and installed shall have prior approval from the Company. All equipment shall meet the project specifications and suitable for installation as required and in compliance with the manufacturers recommendations.
1 6.2 Quality Control 6.2.1 Deliver, store, protect and handle products as per manufacturers and Proponents requirements. Materials, design and manufacture of supports, anchors and thrust blocks shall conform to SAES standards and Code. Selection and application shall conform to SAES standards and codes.
6.2.2
6.2.3 6.3
Installation 6.3.1 All thrust blocks shall be as per Proponent Standard Drawings. All thrust blocks shall be designed for maximum working pressure of 1379 kPa (2000 psi). Thrust blocks shall be cast with not less than 0.02 m. bearing against the fitting and not less than 0.28 m. bearing against the soil. Thermoplastic pipes shall be protected from contact with concrete by tape wrapping. Concrete thrust blocks shall be placed after hydrostatic test for non-restrained gasketed joint RTR piping and neoprene for RTR and thermoplastic pipes.
Page 3 of 4 MACO-QMCP-003
6.3.2
6.3.3

6.3.4 6.3.5 6.3.6
Install in accordance with manufacturers instructions. Install supports at every direction. Provide trapeze hangers for several pipes in parallel and at the same elevations. Exposed steel hangers and supports shall be prime coated. Space pipe hangers in accordance with design specifications. All HVAC equipment, which is floor, mounted shall be set on solid concrete base. Provide templates, anchor bolts and accessories for mounting and anchoring equipment.
6.3.7 6.3.8 6.3.9
6.3.10 Construct supports of steel members. Brace and fasten with flanges bolt to structure. 6.3.11 Provide curbs for mechanical roof installation at 300-mm (12-Inch) minimum high above roofing surface. Flash and counter flash with sheet metal. Seal watertight.
7.0
ATTACHMENTS Inspection and Test Plan Quality Record
Page 4 of 4
MACO-QMCP-003

DOCUMENT TITLE:
PROCEDURE FOR: VIBRATION ISOLATION

Index 1 2 3 4 5 6 7 Scope Purpose Definitions Safety References Quality Procedure Documentation Page 2 2 2 2 2 2 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Vibration Isolation
Page 1 of 4
MACO-QMCP-004

VIBRATION ISOLATION
1.0 SCOPE 1.1 This covers procedures and items to be checked and verified for the installation of vibration isolation of the appropriate sizes and proper loading for HVAC system.
2.0
PURPOSE 2.1 To provide vibration isolators of the appropriate sizes and proper loading to meet the specified deflection requirements in conformance with manufacturers recommendations.
3.0
DEFINITIONS 3.1 3.2 3.3 HVAC QCP ITP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
4.0
5.0
REFERENCES 5.1 5.2 5.3 SAES-K-001 SAES-K-100 ASHRAE Heating, Ventilating and Air-Conditioning Saudi Aramco Mechanical Code (HVAC) American society of Heating, Refrigeration and Air- conditioning Engineers.
6.0
QUALITY PROCEDURES 6.1 Installation. 6.1.1 Install in accordance with manufacturers instructions.
Vibration Isolation
Page 2 of 4
MACO-QMCP-004

6.1.2 6.1.3
Install isolation for motor-driven equipment. Provide flexible duct connectors between air handling unit or fans and distribution ductwork. On closed spring isolators, adjust so side stabilizers are clear under normal operating conditions. Prior to making piping connections to equipment with operating weights substantially different from installed weights, block up equipment with temporary shims to final height. When full load is applied, adjust isolators to load to allow shim removal.
6.1.4
6.1.5
6.2
Provide pairs of horizontal limits springs on fans with more than 6.0 inch (1.5 kPa) static pressure and on hanger supported, horizontally mounted axial fans. Provide resiliently mounted equipment, piping and ductwork with seismic snubbers. Each inertia base shall have minimum of 4 seismic snubbers located close to isolators. Snub equipment designated for post disaster use to 0.05 inch (1.5 mm) maximum clearance. Other snubbers shall have clearance between 0.15 inch (4.0 mm) and 0.25 inch (7.0). Support piping connections to isolated equipment resiliently for scheduled distance to nearest flexible pipe connector as follows: 6.4.1 6.4.2 6.4.3 6.4.4 Up to 4.0 inch (100 mm) first 3 points of support. 5.0 to 8.0 inch (125 to 200 mm) first 4 points of support. 10.0 inch (250 mm) first 6 points of support. Select 3 hangers closest to vibration source for minimum 1.0 inch (25 mm) static deflection of isolated equipment. Select remaining isolators for minimum 1.0 inch (25 mm) static deflection or static deflection of isolated equipment.
6.3
6.4
Vibration Isolation
Page 3 of 4
MACO-QMCP-004

EQUIPMENT ISOLATION SCHEDULE Equipment Air handling Unit Air Cooled Condensing Packaged A/C Units (Check manufacturers literature) Packaged A/C units on roof Workshop Equipment Isolator Neoprene pads Neoprene Pads Not required for on grade installation On roof curb with Neoprene pads Minimum operating Deflection 0.2 0.2 Isolation Efficiency -
As per manufacturers recommendations
7.0
DOCUMENTATION Inspection and Test Plan
Vibration Isolation
Page 4 of 4
MACO-QMCP-004

DOCUMENT TITLE:
PROCEDURE FOR: AIR HANDLING UNIT

Index Page
1 2 3 4 5 6 7
Scope Purpose Definitions Safety References Equipment Units Documentation
2 2 2 2 2 3 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Air Handling Unit
Page 1 of 5
MACO-QMCP-005

AIR HANDLING UNIT

1.0 SCOPE 1.1 This procedure covers for inspection to be followed during installation of Air Handling units as per project specifications and accepted international codes and standards. This procedure shall be used in conjunction with applicable manufactures installation and maintenance manual.
1.2
2.0
PURPOSE 2.1 To ensure that all items required by this contract shall conform to project specifications and construction drawings.
3.0
DEFINITIONS 3.1 HVAC 3.2 QCP 3.3 ITP - Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection of Test Plan
4.0
5.0
REFERENCE 5.1 17-SAMSS0503 5.2 ARI 5.3 5.4 SAES-K-001 SAES-K-002 NEMA Frame Motors American Refrigeration Institute Heating, Ventilating and Air-Conditioning Air-Conditioning Systems for Essential Operating Facilities
Air Handling Unit
Page 2 of 5
MACO-QMCP-005

5.5 SAES-K-003 5.6 5.7 SAES-K-100 ASHRAE
Air-Conditioning System for Communication Building Saudi Aramco Mechanical Code (HVAC) American Society of Heating, Refrigeration and AirConditioning Engineers Air-Conditioning and Ventilation System
5.8
NEPA-90A
6.0
EQUIPMENT UNITS 6.1 General 6.1.1 Unit shall be central station modular air-handler and shall be delivered to site in one (1) piece. Unit shall be vertical or horizontal draw through as indicated on equipment schedule drawings.
6.1.2
6.1.3 Unit shall consist of a fan and coil section, filter section and mixing box section as indicated on the drawings. 6.1.4 All units shall be supplied with a longitudinal 12-gage, galvanized steel structural perimeter base rail that shall serve as a housekeeping rail when unit is installed. Unit shall be capable of shipping fully assembled up to 40 ft. in length. Sections supplied as separate components shall have mating flanges for bolted assembly. Bolts shall be 5/16 inch and be located no further than 6.0 inch in center.
6.1.5 6.1.6
6.1.7 Units shall have provision for installation of instrumentation site. 6.2 Fan Section 6.2.1 Fan shall be constructed of insulated galvanized steel and have formed channel base for integral mounting of and assembly and casing panels. Fan scroll, wheel, shaft, bearing, drives and motor shall be mounted on a structural steel assembly, which shall be isolated from the outer casing with factory-installed 2.0 inch deflection spring isolators and vibrationabsorbent fan discharge seal.
6.2.2
Air Handling Unit
Page 3 of 5
MACO-QMCP-005

6.2.3
Hinged access door shall be provided on both sides of unit when supplied with internal isolation. Each unit shall have one (1) fan wheel and scroll only. Fans shall be double-width, double-inlet type with airfoil or forward curve section blades. Fan wheels shall be keyed to the shaft and shall be designed for continuous operation at the maximum rated fan speed and motor horse power. Fan shafts shall be solid steel, Turned, Ground, Polished and coated with Rust-preventive Oil. Fan bearing shall be self-aligning, pillow block re-greasable ball or rollertype selected for a minimum average lift of 400,000 hrs. A motor shall be mounted within the fan section casing on slide rails having 2 adjusting screws. Fan motor in accordance with specification section 15170 and equipment schedule.
6.2.4 6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
6.2.10 Fan drive shall be designed for a minimum 1.3 service factory, shall be constant-speed adjustable pitch. All drives shall be factory mounted with belts aligned and tensioned. 6.3 Coil Sections 6.3.1 All coil sections shall be constructed of insulated mill galvanized steel panels. All coils shall be factory tested at 400 psig air pressure while submerged in water. Coil performance shall be certified in accordance with ARI standard 410.
6.3.2
6.3.3
6.4 Filter Section 6.4.1 Each filter shall be designed and constructed to house the specific type of filter shown on the equipment schedule. Filter efficiencies shall be in accordance with ASHRAE STD 52. 6.4.2 Filter mixing box section shall accept 2.0 inch thick disposable type fiberglass filter with 20 25% average efficiency as per ASHRAE test methods.
Air Handling Unit Page 4 of 5 MACO-QMCP-005

6.5 Damper Sections 6.5.1 Mixing boxes and filter-mixing boxes shall have opposed blades, interconnecting outside-air and return-air dampers for outdoor units only. 6.5.2 All mixing boxes and filter-mixing boxes shall have a double-walled hinged access door as specified. 6.5.3 All damper blades shall be galvanized steel, housed in a galvanized steel frame and mechanically fastened to a hex axle rotating in stainless steel bearings. 6.5.4 All dampers shall be opposed blade type and rated for a maximum leakage test per square foot of 7.0 cfm. Per ft. at 1.0 inch w.g.
6.6 Access and Plenum Sections 6.6.1 Access and plenum sections shall be installed where indicated on the drawings and shall be as specified on the equipment schedule. Access sections shall have a double walled hinged door and 16 gage floors to protect insulation.
6.6.2
7.0
DOCUMENTATION Inspection and Test Plan. Inspection and Test Record.
Air Handling Unit
Page 5 of 5
MACO-QMCP-005

DOCUMENT TITLE:
PROCEDURE FOR: AIR COOLED CONDENSING UNIT

Index Page
1 2 3 4 5 6 7
Scope Purpose Definitions Safety References Quality Procedures Documentation
2 2 2 2 2 3 4
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Air Cooled Condensing Unit
Page 1 of 4
MACO-QMCP-006

AIR COOLED CONDENSING UNIT

1.0 SCOPE 1.1 This covers procedures for inspection to be followed during installation of aircooled, direct expansion condensing unit and accessories. This covers the inspection of all aspects of air-cooled, direct expansion condensing unit and accessories. This procedure shall be used in conjunction with the applicable manufacturers installation and maintenance instruction manual.
1.2
1.3
2.0
PURPOSE 2.1 To ensure that all equipment required by this contract shall conform to project specifications and construction drawings. This procedure shall ensure that the main inspection requirements are met and that the findings and corrective actions are followed. To achieve acceptable workmanship and installation procedures.
2.2
2.3
3.0
DEFINITIONS 3.1 HVAC 3.2 QCP 3.3 ITP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan Proponent
3.5 Company 4.0 SAFETY 4.1
To ensure that work Permit is valid, if applicable and all works done in the safest possible manner consistent with good construction practices.
5.0
REFERENCE 5.1 17-SAMSS0503 NEMA Frame Motors


5.2 5.3 5.4
SAES-K-001 SAES-K100 ASHRAE
Heating, Ventilating and Air-Conditioning. Saudi Aramco mechanical Code (HVAC) American Society of Heating, Refrigeration and AirConditioning Engineers.
6.0
QUALITY PROCEDURES 6.1 Quality Assurance 6.1.1 Check the service access, filter access, refrigerant piping and condensate piping to ensure adequate clearance for the units. Do not select evaporator/condensing unit operating suction temperatures at less than 36F. Capacity ratings of the units to be ARI certified and that the unit constructed according to UL Standards and carry UL label of approval. Provide special attention to units where significant distances (Vertical and / or horizontal) exist between evaporator and condensing unit locations. Check the approval of all evaporator and condensing unit showing certified combined performance ratings, refrigerant suction temperature and proposed refrigerant line sizes.
6.1.2
6.1.3
6.1.4
6.1.5
6.2
Equipment 6.2.1 Unit shall be a serviceable semi-hermetic type compressor equipped with internal vibration isolation, positive lubrication, crank case heater with relay, motor overload protection, suction and discharge shut-off, service vales, filter dryer, sight glass and a suction and discharge pressure gauge for each refrigerant circuit. Compressor shall be mounted on spring vibration isolators with minimum 95% isolation efficiency. Condenser casing to be fully be mounted on spring vibration isolators with minimum 95% isolation efficiency. Condenser casing to be fully weatherproof, constructed of galvanized steel, zinc phosphatized and finished with enamel.
6.2.2
6.2.3
6.2.4
Page 3 of 4
MACO-QMCP-006

6.3 Installation 6.3.1 6.3.2 Install in compliance with manufacturers recommendations. Install condensing unit to allow sufficient clear space of minimum 3.0 ft. all around for service, maintenance and airflow requirements. For roof locations, mount units on 6.0 inch concrete pad with 6.0 inch margin all around equipment base.
6.3.3
7.0
DOCUMENTATION 7.1 Inspection and Test Plan 7.2 Quality Record
Page 4 of 4
MACO-QMCP-006

DOCUMENT TITLE:
PROCEDURE FOR: PACKAGE AIR CONDITIONING UNIT

Index Page
1 2 3 4 5 6 7
2 2 2 2 3 3 4
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Package Air Conditioning Unit
Page 1 of 4
MACO-QMCP-007

PACKAGE AIR CONDITIONING UNIT

1.0 SCOPE 1.0 This covers instructions for the assigned inspector on procedures and items to check and verify for the installation of Packaged Air-Conditioning units and accessories. This covers the inspection of all aspects of Package A/C Unit and its electrical system. This procedure shall be used in conjunction with the applicable manufacturers installation and maintenance.
1.1
1.2
2.0
PURPOSE 2.0 To ensure that all equipment installed shall be in accordance with the project specifications and manufacturers instructions. This procedure shall ensure that the main inspection requirements are met and that the findings and corrective actions are followed, To achieve acceptable workmanship and installation procedures.
2.1
2.2 3.0
DEFINITIONS 3.1 3.2 3.3 HVAC QCP ITP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
4.0
5.0
REFERENCES 5.1 SAES-K001 Heating, Ventilating and Air-Conditioning.
Page 2 of 4
MACO-QMCP-007

5.2 5.3 5.4 6.0
SAIS-K-100 ARI 17-SAMSS-503
Saudi Aramco Mechanical Code (HVAC) American Refrigeration Institute NEMA Frame Motors
QUALITY PROCEDURES 6.0 Quality Control 6.0.1 Condenser coil guards shall be provided for all units mounted within reach of the public. Cast-in-place roof mounting frame shall also be provided for all units mounted on the roof including flashings. Provide OA, return air and relief air dampers in a factory provided enclosures. All air shall be filtered and bird screens installed. Provide necessary controls for operation of the compressor below the normal temperature of the compressor cutout. Roof top units mounted on slabs or other fixed locations shall be provided with adapters for end discharge and return to the unit.
6.0.2
6.0.3
6.0.4
6.0.5
6.1
Installation 6.1.1 Install the unit on the concrete curb as required by the job conditions and as recommended by the manufacturer and install proper flashing and counter flashings. Set the unit in place, taking care to protect the adjacent roofing and connect the supply and return ductwork. Make electrical connections, making sure that these do not block access to any part of the equipment requiring servicing. Have the factory service person check out the unit and make a written report.
6.1.2
6.1.3
6.1.4
6.2
Balancing and Testing 6.2.1 Operate the unit and check for proper air quantity supply, noise and correct operations.
Page 3 of 4
MACO-QMCP-007

6.2.2
Report the airflow, static pressure, voltage and current draw of each item, refrigerant pressure readings etc. as required by specifications.
7.0
DOCUMENTATION 7.1 7.2 Inspection and Test Plan Quality Record
Page 4 of 4
MACO-QMCP-007

DOCUMENT TITLE:
PROCEDURE FOR: DUCTWORKS

Index Page
1 2 3 4 5 6 7
2 2 2 2 2 3 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Ductworks
Page 1 of 5
MACO-QMCP-008

DUCTWORKS
1. SCOPE This covers procedures for inspection to be followed during installation and leak testing of HVAC Ductworks. This covers inspection of all aspects of duct works This procedure shall be used in conjunction with applicable manufacturers instructions. 2. PURPOSE 2.1 To ensure that all items required by this contract shall conform to project specifications and construction drawings. 2.2 This procedure shall insure that the main inspection requirements are met and that the findings and corrective actions are followed. 3. DEFINITIONS 3.1 3.2 HVAC QCP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
3.3 ITP
4. SAFETY 4.1 To ensure that Work Permit is valid, if applicable and all works done in the safest possible manner consistent with good construction practices.
5. REFERENCES 5.1 SAES-K-001 5.2 SAES-K-100 5.3 SAES-M-100

Ductworks
Heating, Ventilating and Air-Conditioning Saudi Aramco Mechanical Code (HVAC) Saudi Aramco Building Code

5.4 NFPA 90A 5.5 NFPA 91 5.6 AWS D-9.1 5.7 SMACNA 5.8 SMACNA 5.9 UL 181 5.10 ASTM A-36 5.11 ASTM A-526
Installation of Air-Conditioning and Ventilating System. Installation of Blower and Exhaust System Welding of sheet Metal HVAC Air Duct Leakage Test Manual HVAC Metal and Flexible Duct Construction Standards. Factory made Air Ducts and Connectors Structural Steel Requirements for Steel Sheets, Zinc-coated by hot dip Process Steel Sheets, Carbon and High Strength, Low-alloy Hotrolled and Cold-rolled Fire Damper Installation Guide
5.12 ASTM A-568 5.13 SMACNA 6. QUALITY PROCEDURES
6.1 Fabrication and Installation. 6.1.1 Perform fabrication in accordance with SMACNA Duct Construction Metal and flexible . Provide duct materials, gauges, reinforcing and sealing for operating pressures. Provide T-bends and elbows with radius of not less than 1 times width of duct on centerline. Provide air foil turning vanes for rectangular elbows. Fabricate continuously welded round and rectangular duct fittings two gages heavier than the duct gages. Joints shall be minimum 4 cemented slip joint. Prime coat all welded joints. Apply interior of duct coats compatible with fume exhausted. Install all fabricated ducts in accordance with SMACNA HVAC Duct Construction Standards Metal and Flexible.
6.1.2
6.1.3
6.1.4 6.1.5
Ductworks
Page 3 of 5
MACO-QMCP-008

6.1.6
Provide openings to accommodate thermometers, controllers and pilot tube for testing of system complete with metal can with spring device or screw to ensure against air leakage. Ducts must be located in sufficient spaces around equipment to allow normal operating and maintenance activities. Connect diffuser to low-pressure ducts directly held in place by strap or clamp. Connect flexible ducts to metal ducts with adhesive plus tape, draw bands and sheet metal screw.
6.1.7
6.1.8
6.1.9
6.1.10 All open ductwork must be temporarily closed with metal or taped polyethylene to prevent ingress of dust during construction. 6.1.11 All flexible connectors shall not be more than one 90 turn and flexible duct are not allowed to be used in changing of direction. 6.2 Duct Hangers and Supports 6.2.1. All materials shall be galvanized steel band iron. 6.2.2. Wall supports shall be galvanized or fabricated angle bracket. 6.2.3. Arrange hangers to prevent transmission of vibration from piping to the building structure and allow for expansion and contraction. Clearance for application of the specified insulation without cutting either pipeline covering or fitting covering in installation of hangers and fitting shall be provided. 6.2.4. Flash vents and soil pipes projecting 75-mm minimum above finished roof surface with lead worked 25-mm minimum in to hub, 200-mm minimum clearance on sides with 600 x 600-mm sheet. 6.2.5. Flash floor drains in floors with topping over finished areas with lead 250 mm clear on sides with minimum 910 x 910-sheet size. 6.2.6. Seal floor, shower, mop, sink, drains watertight to adjacent materials. 6.2.7. Provide curbs for mechanical roof installations, 300 mm minimum high above roof surface. Adjust storm collars tightly to pipes with bolts caulk around top edge. Use storm collars above roof jacks. Screw vertical flange section to face of curb.
Ductworks
Page 4 of 5
MACO-QMCP-008

6.3 Testing 6.3.1 6.3.2 Duct testing shall be by light test method. A flash of light shall be introduced inside the finished duct works to check if any ray of light is escaping form the inside of duct to signify openings, cracks or damages. Test shall be done during the night for pressure duct system.
6.3.3
6.4
Cleaning
6.4.1. Duct system shall be clean with force air at maximum allowable velocity through duct to remove accumulated dust. 6.4.2. Clean all duct system with high power vacuum machines. Protect installed ducts from dust and dirt. Provide access in to duct work for cleaning purposes. 7. ATTACHMENTS 7.1 Inspection and Test Plan 7.2 Quality Record
Ductworks
Page 5 of 5
MACO-QMCP-008

DOCUMENT TITLE:
PROCEDURE FOR: DUCTWORKS ACCESSORIES

001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Ductworks Accessories
Page 1 of 4
MACO-QMCP-009

DUCTWORKS ACCESSORIES
1.0 SCOPE 1.1 This covers procedures for inspection to be followed during installation of turning vanes, duct access doors, fire dampers, combination fire / smoke damper, flexible connectors, volume and control dampers.
1.2 This covers the inspection of all aspects of ductwork accessories. 1.3 This procedure shall be used in conjunction with the applicable manufacturers installation and maintenance instruction manual. 2.0 PURPSOSE 2.1 To ensure that all items required by this contract shall conform to project specifications and construction drawings. 2.2 This procedure shall insure that the main inspection requirements are met and that the findings and corrective actions are followed. 3.0 DEFINATIONS 3.1 HVAC 3.2 QCP 3.3 ITP 4.0 SAFETY 4.1 To ensure that Work Permit is valid, if applicable and all works done in the safest possible manner consistent with good construction practices. Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
5.0
REFERENCES 5.1 SAES-K-001 5.2 SAES-K-100 5.3 SAES-M-100/UBC Heating, Ventilating and Air-Conditioning Saudi Aramco Mechanical Code (HVAC) Saudi Aramco Building Code
Page 2 of 4
MACO-QMCP-009

5.4 NFPA 90A 5.5 SMACNA 5.6 SMACNA 5.7 UL 33 5.8 ASHRAE
Inspection of Air-Conditioning and Ventilating System. Fire Damper Installation Guide HVAC Metal and Flexible Duct Construction Standards. Heat Responsive Links for Fire Protection Services. American Society of Heating Refrigeration and AirConditioning Engineers.
6.0
QUALITY PROCEDURES 6.1 Material Control 6.1.1 All materials shall be delivered, protected and handled to site in accordance with the Companys requirements. 6.1.2 Protect dampers from damages to operating linkages and blades. 6.1.3 All data shall be submitted under provisions of the Company. 6.2 Installation 6.2.1 6.2.2 Install all accessories in accordance with manufacturers instructions. Provide access doors for inspection and cleaning before and after filters, coils, fans and dampers. Provide duct test holes where indicated and required for testing and balancing purposes. Provide fire dampers where ducts and outlets pass through fire rated components as required by SAES-M-100/UBC and NFPA 90-A. Demonstrate re-setting of fire dampers to the company. Provide flexible connections immediately adjacent to equipment in ducts associated with fans and motorized equipment supported with vibration isolators.
6.2.3
6.2.4
6.2.5 6.2.6
Page 3 of 4
MACO-QMCP-009

6.2.7
Provide balancing dampers at points on supply, return and exhaust system where branches are taken from larger ducts for air balancing. Install minimum 2 ducts width from duct take-off. Provide balancing dampers on duct take-off to diffuser, gullies and registers regardless of dampers are specified as part of the diffuser, gull or register assembly.
6.2.8
7.0 ATTACHMENTS 7.1 Inspection and Test Plan 7.2 Quality Record
Page 4 of 4
MACO-QMCP-009

DOCUMENT TITLE:
PROCEDURE FOR: DUCTWORKS INSULATION

Index Page
1 2 3 4 5 6 7
2 2 2 2 2 3 4
001 ISSUE NO.
04/04/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Ductworks Insulation
Page 1 of 4
MACO-QMCP-010

DUCTWORKS INSULATION
1.0 SCOPE 1.1 This covers procedures for inspection to be followed during installation and application of insulation, jackets and accessories for Ductwork Insulation. This covers the inspection of all aspects of ductwork insulation works. This procedure shall be used in conjunction with the applicable manufacturers installation and maintenance instruction manual.
1.2 1.3
2.0
PURPOSES 2.1 To ensure that all ductworks required by this contract shall conform to the project specifications and construction drawings. This procedure shall ensure that the main inspection requirements are met and that the findings and corrective actions are followed. To achieve acceptable workmanship and installation of equipments.
2.2
2.3 3.0
DEFINITIONS 3.1 HVAC 3.2 QCP 3.3 ITP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
4.0
5.0
REFERENCES 5.1 SAES-K-001 5.2 SAES-K-100 Heating, Ventilating and Air-Conditioning. Saudi Aramco Mechanical Code (HVAC)
Page 2 of 4
MACO-QMCP-010

5.3 SAES-M-100 5.4 SMACNA
Saudi Aramco Building Code Sheet Metal and Air-Conditioning Contractors National Association. National Fire Protection Association Aluminum and Aluminum-alloy Sheet and Plate Mineral Fiber Blanket and Felt Insulation Mineral Fiber Block and Board Thermal Insulation Surface Burning Characteristics of Building Materials Water Vapor Transmissions of Materials HVAC Duct Construction standards Metal and Flexible
5.5 NFPA 5.6 ASTM-B-209 5.7 ASTM C-553 5.8 ASTM C-612 5.9 ASTM E-84 5.10 ASTM-96 5.11 SMACNA
6.0
QUALITY PROCEDURES 6.1 Install material in accordance with manufacturers instructions. 6.2 Insulated ductwork conveying air below ambient temperature. 6.2.1 6.2.2 Provide insulation with vapor barrier jackets. Finish with tape bands and vapor barrier jacket or stickpins where applicable for wide ducts. Continue insulation through walls, sleeves, hangers and other duct penetrations. Do not use combustible duct bands in return air plenum. Insulate entire system including fittings, joints, flanges, flexible connections and expansion joints.
6.2.3
6.2.4
6.3 Insulated ductwork conveying air above ambient temperature. 6.3.1 6.3.2 Provide with standard vapor barrier jacket. Insulate fittings and joints. Where service access is required, bevel and seal ends of insulation.
Page 3 of 4
MACO-QMCP-010

6.4 For ductwork exposed in mechanical equipment rooms or in finished spaces below 10-ft. (3.0 M) above finished floor, finish with aluminum jacket. 6.5 For ductwork exposed to outside, finish with all-purpose weatherproof jacket. When specified in section 5500 for cladding, finish with stainless steel 304 jackets.
7.0
DOCUMENTATION Inspection and Test Plan Quality Record
Page 4 of 4
MACO-QMCP-010

DOCUMENT TITLE:
PROCEDURE FOR: MECHANICAL IDENTIFICATION

Index Page
1 2 3 4 5 6 7
2 2 2 2 2 3 5
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Mechanical Identification
Page 1 of 5
MACO-QMCP-011

MECHANICAL IDENTIFICATION
1.0 SCOPE 1.1 This covers procedures for inspection to be followed during the marking and identification of materials to identify HVAC equipment. This covers the inspection of all aspects of mechanical identification.
1.2 2.0
PURPOSE 2.1 To ensure that all items required by this contract shall conform to project specifications and construction drawings. This procedure shall insure that the main inspection requirements are met and that the findings and corrective actions are followed.
2.2
3.0
DEFINITIONS 3.1 HVAC 3.2 QCP 3.3 ITP Heating, Ventilating and Air-Conditioning. Quality Control Procedure. Inspection and Test Plan
4.0
5.0
REFERENCES 5.1 5.2 5.3 5.4 5.5 SAES-K-001 SAES-B-067 SAES-M-100 SAES-K-100 ASME A-13.1 Heating, Ventilating and Air-Conditioning. Safety Identification and Color Codling Saudi Aramco Building Code Saudi Aramco Mechanical Code (HVAC) Scheme for the Identification of Piping System

5.6
UMC
Uniform Mechanical Code
6.0
QUALITIES PROCEDURES 6.1 Piping Identifications Install plastic nameplates with corrosive -resistant mechanical fasteners or adhesives. Apply with sufficient adhesive to ensure permanent adhesion and seal with clear lacquer. Install tags with corrosion resistant chain. Install plastic pipe markers completely around pipe in accordance with manufactures instructions. Identify air-handling units, condensing units, exhaust fans and other equipment with plastic nameplates. Small devices may be identified with tags. 6.4.1 Identify control panels and major control components outside panels with plastic nameplates. Identify thermostats relating to terminal boxes or valves with nameplates. Identify valves and air-terminal units with numbered tags. Tag automatic controls, instruments and relays to conform with control schematic. Identify piping, concealed or exposed with plastic pipe markers. Use tags on piping (20 MM) and smaller. Identify ductwork with plastic nameplates. Identify air-handling units with identification number and area served.
6.2 6.3
6.4
6.4.2 6.4.3 6.4.4
6.4.5
6.4.6
6.5 6.6
Provide ceiling tacks to locate vales or dampers above T-bar type panel ceilings. Attach to each valve an engraved, plastic identification tag indicating valve manufacturer, style, size, normal position, contents of pipe and sequential ID number. Tag identification to be as follows :
Service Cold Drinking Water
Abbreviation DW ( Cold )
Page 3 of 5
MACO-QMCP-011

Hot Drinking Water Utility Water Fire Water Compressed Air
DW ( Hot ) UW FW CA
6.7
HVAC Equipment An identification tag or nameplate made of 316 stainless steel shall be attached to each item of equipment. The tag shall be marked by raised letter as follows : 6.7.1 Purchase Order Number 6.7.2 Manufacturer
6.7.3 Part / Model Number 6.7.4 Serial Number 6.7.5 Date of manufacture 6.7.6 Mark / Tag Number 6.8 Safety Color-Code The colors red, green, orange and blue shall be reserved for safety uses described herein: 6.8.1Red shall be used as the color indicator for fire protection equipment and piping as well as emergency stop push button devices and signs. 6.8.2 Green shall be used as the background color indicator for locations of emergency safety equipment including first aid equipment, safety showers and eye-wash units. Orange shall be used as the color indicator for inlet and outlet block valves for pressure relief valves. Blue shall be used as the color indicator for chilled water, drinking water and utility water.
6.8.3
6.8.4
Page 4 of 5
MACO-QMCP-011

7.0
Page 5 of 5
MACO-QMCP-011

DOCUMENT TITLE:
PROCEDURE FOR: TESTING & BALANCING OF MECHANICAL SYSTEMS

Index Page
1 2 3 4 5 6 7
2 2 2 2 2 2 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Testing & Balancing 0f Mechanical Systems
Page 1 of 4
MACO-QMCP-012

TESTING & BALANCING OF MECHANICAL SYSTEMS

1.0 SCOPE 1.1 This covers procedures for inspection to be followed during testing, balancing and adjusting of air moving equipment and air distribution system as per project specifications and accepted international codes and standards.
2.0
PURPOSE 2.1 To conduct airside balancing of HVAC system in accordance with the project specifications and accepted international codes and standards.
3.0
DEFINITIONS 3.1 HVAC 3.2 QCP 3.3 ITP Heating, Ventilating and Air-Conditioning Quality Control Procedure Inspection and Test Plan
4.0
5.0
REFERENCES 5.1 5.2 AABC ASHRAE Associated Air-Balance Council American Society of Heating, Refrigeration and Air-Conditioning Engineers
5.3 5.4 5.5 5.6
SAES-K001 Heating, Ventilating and Air-Conditioning. SAES-K100 ARI NFPA 90 A Saudi Aramco Mechanical Code (HVAC) American Refrigeration Air-Conditioning and Ventilation System
Page 2 of 4
MACO-QMCP-012

6.0
QUALITY PROCEDURES All HVAC equipment to be supplied and installed shall have prior approval form SAPMT. All equipment shall meet the project specifications and suitable for installation as required and in compliance with the manufacturers recommendations. 6.1 Testing 6.1.1 test all systems and equipment installed under this division to demonstrate proper operation as per SAES-K-001, Para 6.3 & 6.1. All T & B personnel shall be quailed as per SAES-K-001, Para 6.2. Place HVAC systems and equipment in to operation and continue operation during each working day of balancing and adjusting. Set-up and balance air distribution system. Set air handling unit discharge temperature as shown in the equipment schedule. Measure discharge air temperature. Adjust leaving air temperature to schedule setting at design. After individual box balancing, set all boxes to full heat and measure zone flows with flow measuring devices. Test equipment vibration and vibration isolation system in accordance with methods and procedures given in the testing, adjusting and balancing chapter of ASHRAE Systems Handbook. Provide testing on air-handling units located on roof and exhaust fans located also on the roof.
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.2
Air-Balancing 6.2.1 Adjust fan RFM to design requirements. Record motor full load amperes. Make pilot tube traverse of main supply ducts and adjust fans to design airflow rates. Record system operating static pressures, suction and discharge. Adjust system for design re-circulated air CFM. Adjust main and zone supply, return and exhaust air ducts to proper design CFM.
6.2.2
Page 3 of 4
MACO-QMCP-012

6.2.3
Check air velocity across each duct-mounted smoke detector. Verify that the minimum velocity recommended by the smoke detector manufacturers installation instructions is present. Make changes in pulleys, belts and dampers or addition of dampers required for correct air-balance as per AABC requirements. After coil adjustments and VAV box setting, re-check settings as required.
6.2.4
6.2.5 6.3
Operation 6.3.1 Check final air velocity across each duct-mounted smoke detector. Verify that the minimum velocity recommended by the smoke detector manufacturers installation instructions is present. If detectors are equipped with a visual airflow wheel, verify that wheel is operating properly. Record sling psychometric readings of both dry and wet bulb temperatures for outside air conditioning, air handling unit (air and out), room conditions and thermostat settings and moisture transducer field calibrations.
6.3.2
6.4
Acceptance 6.4.1 The following items are to be completed before requesting a final inspection:
System Balancing Control System Checkout Operating Instructions
6.4.1
A representative of the balancing Agency is to be present to assist during final inspections. Contractors technicians shall be available to operate the system, make adjustments and assist in final inspections.
7.0
Page 4 of 4
MACO-QMCP-012

DOCUMENT TITLE:
PROCEDURE FOR: WELDING OF STRUCTURAL AND PIPING

Index Page
1 2 3 4 5 6 7
2 2 2 2 2 2 3
001 ISSUE NO.
04/09/09 ISSUE DATE
APT PREPARED BY
GJR CHECKED BY
NZ APPROVED BY
Welding of Structural and Piping
Page 1 of 3
MACO-QMCP-013

WELDING OF STRUCTURAL AND PIPING

1.0 SCOPE The Quality Procedures shall apply for the welding of structural steel and carbon steel pipe in compliance with the Contact drawings and specifications. 2.0 PURPOSE The Quality Procedure has been developed to describe the main works of operation and performance with the Quality Control activities during welding. 3.0 DEFINITIONS 3.1 QMP 3.2 QCP 3.3 ITP 3.4 COMPANY : Quality Manual Procedures : Quality Control Procedures : Inspection and Test Plan : Proponent
4.0
REFERENCES
4.1 4.2 4.3 4.4
SAES-M-001 12-SAMSS-007 SAES-W-011 SAES-H-001
: Basic criteria for steel structures : Miscellaneous Steel Structure : Welding Requirements for on-plot piping : Specification requirements for industrial coating
5.0
QUALITY SYSTEM MACO shall monitor as a minimum some form of Quality system as means of ensuring that the product conforms to Proponent specification requirements.
6.0
PROCEDURE & INSPECTION AND TEST PLAN 6.1 Procedures. MACO works shall procure documented procedures and submit for approval. These Procedures are to make reference to the applicable specification standards.
Page 2 of 3
MACO-QMCP-013

( a ) Material The Procedure documents. ( b ) Welding Procedures The Procedure is to describe the welding process with specifications, type and grade and control during welding depending on the process itself. ( c ) Fit-up / Cutting and Assembly. The Procedure is to address clearance, dimensions, tolerances, alignment, tack welds and pre-heat ( if any ). ( d ) Qualifications The procedure shall not ignore the qualification requirements the welders, welding inspectors to be as per Saudi Aramco specification requirement. (e) Pre-Heat. If Pre-heat is required, the procedures shall be produced to cover this activity. It is to ensure that the temperature rates are monitored according to Contract specification and applicable standards. (f) Calibration The procedure shall cover the requirement of calibration instruments / equipment ( Power supply ), ampere, voltage- evidence of valid calibration shall be maintained as per SAES-W-011, Par 19.2 (g) Control of Consumables. Control of consumables shall be followed for the welding activity such as low hydrogen electrodes to monitor would be storage temperature and applicable type for particular material as per SAES-W-011. shall cover material inspections and
7.0
DOCUMENTATION None
Page 3 of 3
MACO-QMCP-013

Complete Quality Manual Vol 2 Rev. 2010

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Complete Quality Manual Vol 2 Rev. 2010

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THIS QUALITY MANUAL IS THE ONLY CONTROLLED AND VALID VERSION.

QA / QC MANUAL VOL. 2 CONSTRUCTION PROCEDURES

KINGDOM OF SAUDI ARABIA

DOCUMENT NO. MACO-QM-001

QA/QC MANUAL VOL. 2 CONSTRUCTION PROCEDURES

ISSUED FOR APPROVAL QA/QC Quality Manual SIGNATURE/DATE

Revision 1 April 1, 2009

DOCUMENT NO. MACO-QM-001 VOL. 2

QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0

QUALITY ASSURANCE/QUALITY CONTROL MANUAL

Description Prepared By: Approved By: Approved By: Approved By:

Y.S. Bahrawy N. M. Zahrani S. M. Zahrani

Projects Gen. Manager Assistant General Manager General Manager

Quality Manual Vol. 2

QUALITY ASSURANCE/QUALITY CONTROL MANUAL Doc. No. MACO-QMP-001 Rev. 0

QUALITY ASSURANCE/QUALITY CONTROL MANUAL MACO-QM-001

Purpose of Revision Submitted for Approval.

Issue Date April 01, 2009

-iiQuality Manual Vol. 2 MACO-QM-001

QUALITY CONTROL/ASSURANCE MANUAL Quality Construction Procedures

TABLE OF CONTENTS QUALITY CONSTRUCTION PROCEDURES

PROCEDURE DESCRIPTION CIVIL WORKS

QUALITY CONTROL/ASSURANCE MANUAL Quality Construction Procedures

TABLE OF CONTENTS QUALITY CONSTRUCTION PROCEDURES

QUALITY CONTROL/ASSURANCE MANUAL Quality Construction Procedures

INSTALLATION OF BATTERIES AND CHARGERS UNDERGROUND ELECTRICAL DUCT BANKS/MANHOLES

TABLE OF CONTENTS QUALITY CONSTRUCTION PROCEDURES

PROCEDURE DESCRIPTION MECHANICAL WORKS

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

PROCEDURE FOR: SURVEYING

DOCUMENT NO.: MACO-QCCP-001

001 ISSUE NO.

04/09/09 ISSUE DATE

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

SURVEY CHECKLIST QCCP-001-01-SC

Contract No.: _________________________ Location: _________________________

Drawing No: _________________________

COORDINATES AS PER ACTUAL DRAWING

ELEVATION AS PER ACTUAL DRAWING

Remarks: _______________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________

Signature: Name: Date:

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

PROCEDURE FOR: SITE PREPARATION

DOCUMENT NO.: MACO-QCCP-002

001 ISSUE NO.

04/09/09 ISSUE DATE

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

ASTM C136: ASTM D 3017:

Royal Commission Specifications: 02251 02220

Compaction and Testing of Earthwork Structure Excavation and Backfill

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

Trenching, Bedding, Backfilling and Compacting

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

QUALITY CONTROL/ASSURANCE MANUAL Construction Procedures

SITE PREPARATION CHECKLIST QCCP-002-01-SP

Contract No.: _________________________ Location: _________________________

Contract No.: _ Location: _

Remarks: _ ______________

Contract No.: _ Location: _

Remarks: _ ______________

Contract No.: _ Location: _

Remarks: _ ______________

Contract No.: _ Location: _

Remarks: _ ______________